Its pretty straightforward to assemble and install these but here are the basics and some things to watch out for: Removal is obviously straightforward and poses no hazards.The pics show the mating surface on an old and 5 times repainted tank so hopefully yours is in better shape. I took off a lot paint surrounding the hole because I was in a hurry and I'm blasting & repainting this tank anyway. Note:You only need to make sure the surface is flat smooth and clean. The gasket is thick and seals well. If you look close at the relief pic you can see you don't need to make a lot of room for the new screen to slide in. A few strokes on both sides with a half round file and presto you're done. Note: Use outward strokes only to minimize or eliminate shavings getting into your tank. Use a magnet, blow nozzle or whatever you have to make sure those little shavings are out of your tank. Don't forget to make sure the edges of the relief are flat and smooth when you are done. Take a flat file to it to make sure. I greatly prefer the 90 angle to the straight fitting as it just looks cleaner on the bike plus if you don't use a ridiculous amount of hose its gonna kink. I like my 90's to be rear- ward of the petcock if you are looking at the side of the bike. That means on your right side petcock you need to remove not only the straight fitting but switch the dead plug to the other side side and then install the 90. Big note: Be really careful with the small tubular screen that is behind the fittings. If you are pointing the petcock downwards when unscrewing the fittings it will fall out. Also make sure it is centered when screwing the fittings in as it will crush and get out of whack as you tighten. It is made to ride in the recess on the fitting so keep an eye on it. Be very careful as it is not hard to seriously gouge or even break the 90 fitting when tightening it. When tight enough it is at exactly a 90 degree angle to the back of the petcock. I recommend leaving it there. ***The petcock comes with two 90 degree fittings try them both as 1 will end up where it needs to be and 1 points off toward Pluto when its tight. The threads are cut specific to the side you are installing them on so don't get discouraged if the first one ends up at a wacky angle. The other one will do the trick. Took me a bit to figure that one out as I kept installing the right one first by sheer luck. Thanks to Bart Snell for letting me in on the secret. When applying the teflon tape to the petcock cover the threads above the O-ring only. There is no need to wrap over the o-ring and will probably compromise it's effectiveness. 1 1/2-2 wraps is all you need. Screw the petcock into the adapter plate by hand until it starts to get tight, then take a look. It will be almost be perfectly lined up. Align them til they are right on then look at the underside of the plate. The petcock o-ring will be almost exactly flush with the bottom of the plate. You are done. Bolt the assembly onto your tank with the supplied bolts using moderate pressure. You don't need a torque wrench for this so be firm but not so much pressure as to A)displace the gasket or B)strip your threads out. Cover your vacuum barbs with the supplied caps, run your lines and you're on the road with no more worries about gas in your oil.
Its pretty straightforward to assemble and install these but here are the basics and some things to watch out for:
If you look close at the relief pic you can see you don't need to make a lot of room for the new screen to slide in. A few strokes on both sides with a half round file and presto you're done. Note: Use outward strokes only to minimize or eliminate shavings getting into your tank. Use a magnet, blow nozzle or whatever you have to make sure those little shavings are out of your tank. Don't forget to make sure the edges of the relief are flat and smooth when you are done. Take a flat file to it to make sure. I greatly prefer the 90 angle to the straight fitting as it just looks cleaner on the bike plus if you don't use a ridiculous amount of hose its gonna kink. I like my 90's to be rear- ward of the petcock if you are looking at the side of the bike. That means on your right side petcock you need to remove not only the straight fitting but switch the dead plug to the other side side and then install the 90. Big note: Be really careful with the small tubular screen that is behind the fittings. If you are pointing the petcock downwards when unscrewing the fittings it will fall out. Also make sure it is centered when screwing the fittings in as it will crush and get out of whack as you tighten. It is made to ride in the recess on the fitting so keep an eye on it. Be very careful as it is not hard to seriously gouge or even break the 90 fitting when tightening it. When tight enough it is at exactly a 90 degree angle to the back of the petcock. I recommend leaving it there. ***The petcock comes with two 90 degree fittings try them both as 1 will end up where it needs to be and 1 points off toward Pluto when its tight. The threads are cut specific to the side you are installing them on so don't get discouraged if the first one ends up at a wacky angle. The other one will do the trick. Took me a bit to figure that one out as I kept installing the right one first by sheer luck. Thanks to Bart Snell for letting me in on the secret. When applying the teflon tape to the petcock cover the threads above the O-ring only. There is no need to wrap over the o-ring and will probably compromise it's effectiveness. 1 1/2-2 wraps is all you need. Screw the petcock into the adapter plate by hand until it starts to get tight, then take a look. It will be almost be perfectly lined up. Align them til they are right on then look at the underside of the plate. The petcock o-ring will be almost exactly flush with the bottom of the plate. You are done. Bolt the assembly onto your tank with the supplied bolts using moderate pressure. You don't need a torque wrench for this so be firm but not so much pressure as to A)displace the gasket or B)strip your threads out. Cover your vacuum barbs with the supplied caps, run your lines and you're on the road with no more worries about gas in your oil.
When applying the teflon tape to the petcock cover the threads above the O-ring only. There is no need to wrap over the o-ring and will probably compromise it's effectiveness. 1 1/2-2 wraps is all you need. Screw the petcock into the adapter plate by hand until it starts to get tight, then take a look. It will be almost be perfectly lined up. Align them til they are right on then look at the underside of the plate. The petcock o-ring will be almost exactly flush with the bottom of the plate. You are done. Bolt the assembly onto your tank with the supplied bolts using moderate pressure. You don't need a torque wrench for this so be firm but not so much pressure as to A)displace the gasket or B)strip your threads out. Cover your vacuum barbs with the supplied caps, run your lines and you're on the road with no more worries about gas in your oil.
Bolt the assembly onto your tank with the supplied bolts using moderate pressure. You don't need a torque wrench for this so be firm but not so much pressure as to A)displace the gasket or B)strip your threads out. Cover your vacuum barbs with the supplied caps, run your lines and you're on the road with no more worries about gas in your oil.