3 gallons or less in your tank!!

[Phatboyc]

Been running the same setup as jonlafon1 for a year now without a single surge. Before modifications it was another story... Since I run a lot in the backcountry I used to have problems when less than ½ a tank doing prolonged right hand dognuts. Or sled beeing tilted on its right side, simply would not start unless I rocked violently from side to side. (Opening the ports in bottom of the cup)

Are you stock?

 

[Kuzzy]

What benefit does the grommet and elbow have over a common bulkhead fitting?

 

[NYTurbo]

I've installed a number of these PEFI kits. It comes with a new all-billet tank cap with stock-type quick connect fuel fittings. The return line is 5/16" fuel injection hose. Under the machined tank cap, the return line has a 5/16" diameter tube that extends downward about 2" putting it directly into the middle of the basket and below the top of the basket. The basket will always be full until you literally run out of gas. As previously stated, the fuel pump pulls gas from inside the basket. With this system, the fuel pump will always be submerged in gas until you run out completely.
Also, based on the numbers on the pump, I believe it's a 155 liter/hour pump which is about 50% higher volume than a stock pump. It's longer and bigger diameter than stock pump. These kits are very nice but expensive ($620). But, what are we willing to pay to keep engine safe from starvation?

155 lph is a small pump . Others are using a 255 or 340 lph pump

 

[Turboflash]

My mistake - you're right. I meant 255 not 155.

 

[GodSpeedSWE]

Are you stock?

No. Problems occurred both stock and ss240 after modifications and uppgrade to ss 270 no problems what so ever.

 

[GodSpeedSWE]

Resistance to gasoline? Made for the application. Elbow gives a low profile under the seat.

What benefit does the grommet and elbow have over a common bulkhead fitting?

 

[1nc 2000]

Resistance to gasoline? Made for the application. Elbow gives a low profile under the seat.

Being that they are made to be used in fuel and thats what Yamaha used is why I went with the yamaha elbow and grommet.

 

[Kuzzy]

Being that they are made to be used in fuel and thats what Yamaha used is why I went with the yamaha elbow and grommet.

thanks, i have access to steel bulkhead fittings with an elbow (barb or threaded). haven't decided if i want to do that or order the parts from cat. Likely be a bit of a waste, but i could easily make up a return hose that screws on.....ill probably just go with the grommet listed above since i dont have to reinvent the wheel lol.

 

[GodSpeedSWE]

Just make sure the hose have the exact same dimentions as OEM. Important since OD of the FPR is a fair bit larger than OD of the elbow.... stupid design. May be less of a problem in the imperical world but I can assure you it was a big headache to source over here.

Tried to force smaller millimeter dimension on the FPR, went on after some serious wrestling. However after 15seconds of test run in my garage the line burst spraying fuel all over the place... Apparently hurt the hose reinforcement. Less than ideal!

 

[jonlafon1]

Wanted to add some pictures for some that are maybe looking to do the fuel return line mod.. This was the second one I did and I ALMOST went to far outward on my hole placement.. It worked in my favor as the fit was super tight and I have zero concern of this grommet and fuel elbow coming unbuttoned.. Many of these pics are basic things that a lot of guys on here don't need to see, but I feel this is more about the guy that's nervous about doing it or slightly less inclined to do this mod. Its very easy BUT be CAUTIOUS where you drill your hole and obviously remove the fuel pump assembly before drilling and make sure no plastic shavings go into gas tank.. MEASURE 6 times and drill once!!! Not a lot of room and places for the return hole using the grommet > as you have to account for the grommet diameter out and around the hole..

4 feet of fuel line(1/4") .. Go to a automotive store and buy some good fuel line.
also need
3 clamps, rubber cap, fuel elbow, and one grommet.

 

[jonlafon1]

 

[jonlafon1]

 

[jonlafon1]

https://www.amazon.com/DYWISHKEY-Stainless-Single-Stepless-Pincers/dp/B07MX9DKNK/ref=sr_1_15?crid=2HOTD62BVLZOG&keywords=fuel+line+clamps&qid=1636050814&sprefix=fuel+line+clamp%2Caps%2C380&sr=8-15

this is not the kit i have but you get the idea as far clamps and the tool used to install

 

[jonlafon1]

Old fuel return line on upper left side of fuel tank.. remove old hose and plug hole with original grommet and elbow and rubber vacuum line cap or whatever you choose to use

 

[jonlafon1]