DIY: 05 cbr 600rr main fuel line (replace) - 600RR.net
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post #1 of 8 (permalink) Old 10-08-2014, 08:25 PM Thread Starter
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DIY: 05 cbr 600rr main fuel line (replace)

So couple of days ago I noticed strong smell of gasoline while riding and it smells even worse when I stop (at this point I was on the driveway). Well sure enough, gas was all over on the left side where the stator cover is instead of draining from the overflow hose.

At first I thought I might've put too much gas but than why did the stator cover soaked? Well sure enough, after removed the gas tank cover and gained access to the base of the gas tank itself, I found a cut on the house of the main fuel line. I cut the hose where the damage house was but only to find out this fuel line is a one time use only. Well I got me a used main fuel line and decide to fix it myself.

So here's what I did and hopefully will help you along the line I will however skip the process of removing the gas tank cover and the gas tank itself. I did not drain the gas inside the had tank but job would be much easier to do so (drain gas from gas tank)

So I guess I'll start with
1. Remove gas tank cover
2. Remove main fuel line from fuel pump
3. Disconnect all connectors

Fuel pump connector


Red connector and the black 5 prong connector on the right side (clutch)
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post #2 of 8 (permalink) Old 10-08-2014, 08:38 PM Thread Starter
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4. Grab a towel and place on top of the air box, below the upper rail injectors because gas will start coming out once you loosen the 2x 8mm bolt on the upper rail.



5. Use 17 mm for the lower injectors

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note: be extra careful removing the main fuel line cuz of this 2 little washer.




Last edited by venomenon83; 10-08-2014 at 08:51 PM.
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post #3 of 8 (permalink) Old 10-08-2014, 08:50 PM Thread Starter
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5. Now we can take the old damage fuel line out, and...



6. Install the new fuel line and start with lower rail injector.

7. Washer - banjo - washer - 17mm







Now cap it up


Last edited by venomenon83; 10-08-2014 at 08:53 PM.
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post #4 of 8 (permalink) Old 10-08-2014, 09:02 PM Thread Starter
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8. Now we can do the upper rail



Once the upper and lower rail of the fuel line is secured

9. Connect the fuel line to the fuel pump and than all the connectors that was disconnected



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post #5 of 8 (permalink) Old 10-08-2014, 09:11 PM Thread Starter
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Now that the banjos (a,b,c) tighten up we can lower tha gas tank
a) upper rail line
b) lower rail line
c) fuel pump line

Be extra careful when lowering the gas tank, we don't want to kink the hose or bent the copper part

Last edited by venomenon83; 10-08-2014 at 09:13 PM.
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post #6 of 8 (permalink) Old 10-08-2014, 09:19 PM Thread Starter
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10. Give 3 or 5 prime to pump gas in the new main fuel line and fire it up.

While the engine running, observe the upper and lower rail where the new main fuel line are and check gas leak.
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post #7 of 8 (permalink) Old 02-15-2015, 05:39 PM
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No more pictures?
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post #8 of 8 (permalink) Old 02-25-2015, 12:32 PM
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Yeah pictures are gone.. :(
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