African Queens Auto Fuel Tap

From Honda Trail Bike Wiki

[edit] Introduction

African Queens sell an excellent replacement fuel tap system. It provides a lamp that indicates when the bike has reached the reserve tank level of fuel. This not only provides a useful visual indication of the fuel state, but will also help to prevent the reduction of fuel pump life due to starvation when the manual switch is used.

[edit] Installing the indicator light

Removing all of the faring is the easiest way to do this

The best way to do this, is to dismantle the indicator light box, but this is both fiddly and time consuming.However, it is possible to drill all the way through with the box in-situ. If done carefully,the rear hole will be right in the middle of a recess. Open the hole up to 10 mm (in 2mm increments, go for a big drill straight off and you may end up with an egg shaped hole).

Wiring of the light goes:

Red - to live(preferably switched). (see Fitting a power socket for constructing an accessory socket)
Yellow - to negative or ground. (from the accessory socket)
The other connector goes to the bulb.

One complaint is both red & yellow wires are way too short and could do with being at least 6" longer.

To test it's working. with the tap held vertically the black float should sit on the little brass washer, this representing no/low fuel - the light should be on. Lift the float as if it were floating in petrol and the light should extinguish.

[edit] Remove the tank and old float switch

The fuel tank is drained and removed as described in the manual, then the fuel tap is removed.

[edit] Re-use the O-ring

Next, remove the o-ring from the old tap for use on the new boss. Pull the mesh up off the old tap, this makes removal of the o-ring easier.

Place the o-ring in the recess of the threaded boss on the tank and then carefully screw the large union from the African Queens kit onto the tank and slowly tighten it.
Care - Do not overtighten the boss.

[edit] Fit the new tap

Now fit the tap with the nozzle pointing in the direction shown. The nut will only go one way, and one of the threads is left handed so be careful. This is one of those jobs which is a bit trial and error trying to get it to line up and go tight at the same time.

This tap position gives maximum clearance when fitting/removing the tank and allows for a smooth radius in the fuel hose. The hose will be routed down and 180 degrees back on itself to meet the fuel filter.

At this point, (make sure you put the tap in the reserve position before re-fitting the tank) consider putting some fuel in the tank and leave it for a while to check for leaks, and then let it run back out throught the tap, again checking for leaks.

The fuel tap needs a 6mm hose, but the fuel filter needs 8mm (and no less). So a quick disconnect fuel coupling is a useful way of meeting the requirement, Motrax sell a suitable item for around £20. This is the how it looks; the 6mm hose is around 6 inches long.

[edit] Tank complete

The original fuel pipe was cut to be just long enough to join the quick release. Also seen in this photo is the cable from the lamp; it's routed just behind the headstock and follows the main loom down the bike.

[edit] Calibration

So with everything plugged in, bike upright (not on center stand) and the ignition on, the red light should be on. Measure out some fuel and keep pouring it in until the light goes out. You then know how much you have in reserve. It should take 5 or 6 litres before the light will go out giving a reserve range of between 50 - 60 miles.

[edit] External Links

Motrax Fuel Coupling