3 gallons or less in your tank!!

[Turboflash]

I did this mod tonight. Not bad overall. I bought a kit of single ear hose clamps but I couldn't get the one on at the fuel rail side. It's tight in there and the clamp is super tight on the line once over the fitting. I'll just use a hose clamp there. I managed to break the clip on the main fuel line when I removed it. Good news is you can get them at the auto parts store for a few bucks. In case anyone else does the same, here is a link: https://www.autozone.com/fuel-delivery/fuel-line-clip/p/dorman-fuel-line-clip-800-023/604824_0_0
The only other thing to add is the hole is just a bit larger than 1/2". I used a step drill bit at first, but you can't go too far or you'll hit the fuel line. I just used regular bits to finish and ran the 1/2" round and round to get it to the right size as I didn't have bits larger. That was time consuming but it worked.
One more.. When figuring out where to drill the hole, you can use the rubber grommet upside down and you'll see it is about perfect where it can lay flat but close to touching the plastic edges towards the center of the pump. You can then mark and drill with confidence.

I hope you used fuel injection clamp, not just a regular hose clamp.
Also, guys may not realize but from my experience, the fuel rail inlet connection is not standard automotive size. It is slightly larger. I tried evey Dorman size and none fit. This means the 90 deg fitting that mates with the fuel is also not standard. We need to be careful to not break that fitting because you can't go to an auto parts store and buy one.

 

[snowdust]

Yeah I am using fuel injection clamps and just normal fuel line... not the high pressure stuff.

 

[1nc 2000]

1/2" hole is a tight fit.. I needed to put a little lube on the grommet when pushing through.. But i feel this keeps it nice and snug..

Agree, I went with the same size as the original hole and had to use a little lube to get the elbow installed.

 

[Turboflash]

Yeah I am using fuel injection clamps and just normal fuel line... not the high pressure stuff.

Yeah, return line = no pressure. Supply line = up to 60 or more.

 

[GodSpeedSWE]

Yeah, return line = no pressure. Supply line = up to 60 or more.

Lower pressure but certainly not low or no pressure. My line burst after the regulator and it was enough pressure to spray fuel all over the sled and floor. If it had happend on a hot sled it surely would have been a candle....

Edit: just check it out for yourselves when you mount this mod and let the returnline flow through the filler cap.

 

[snowdust]

Yeah, it does return a good stream. You don't need to use fuel injection hose, but there is some pressure there. Part of the reason I decided to use fuel injection clamps over the normal ones just to be safe. (And they look better )

 

[1nc 2000]

With a high volume pump i punched off the return line going back to the tank and my fuel pressure gauge went up over 100 psi. So be carefull not to get your return line pinched between the gas tank and frame near the handle bars....

 

[alain langlois]

Thanks!

Did the modification today, thanks for the information very clever. Smart way to prevent fuel starvation.

 

[HABS 1]

this is a real good write up!! was not aware of the possible fuel starvin problem, going to do this hopefully this weekend, went to canadien tire to get parts last weekend and they didn't have high press line nor good clamps, go figure, had time to kill in cincinnati yesterday got all good stuff at orielys!

 

[SideHogger]

Has anyone ran the return line down the left side (clutch side) of fuel tank?

 

[jonlafon1]

Has anyone ran the return line down the left side (clutch side) of fuel tank?

I think I did on my 2017 no issue.. Just more bend at the end of the fuel line run. This my post pic from a couple years ago on the 2017.

 

[jonlafon1]

Seems to me the exhaust side has more room to run the hose under the seat?

 

[HABS 1]

i just did this mod friday night and wanted to run it down left side also for that reason, but it routes nicer just going up right side imo

 

[SideHogger]

Seems to me the exhaust side has more room to run the hose under the seat?

Just trying to make it a clear, clean run and less things running over top of motor.

 

[SideHogger]

i just did this mod friday night and wanted to run it down left side also for that reason, but it routes nicer just going up right side imo

Looking at it all now and their does seem to be more room on the right side.