Have had fuel tank off on my K100RT and replaced the fuel supply line from tank to fuel rail, but now have fuel pouring out from middle of engine somewhere. Only place I can think of is the line to pressure regulator valve . The return line from fuel rail goes in behind air box above injectors so can't see in there. What is involved in getting to this valve ? I can't get any info from my manual to help me. Any help appreciated.
Allan

If you haven't put new fuel lines on it Allan do it now, they probably are 30 years old and had a 10 year working life. Make sure you get lines that are suitable for use inside the tank as you should replace the line in there.
You need to take the air filter box off to get to the pressure regulator.
I have also sent a PM with a link.

yep even sometimes just moving the lines forms cracks and leaks on those old heat affected and past use by date lines

aim for 30r10 lines x 8mm inner (designed for internal and submersion use ) ...next option is 30r9 and so forth by the time you get to 30r7  double think installing them at all ...with ethanol in small quantities of fuel these days (and sometimes in large quantities )  the ethanol penetrates the lower grade lines and you can smell it escaping quite readily

unfortunately the wall thickness of the lines increases as you get better stuff , so look for the appropriate clamps to suit the new line whilst your shopping ,,,try and get a rounded edge of the clamps if possible

good luck mate

Are you sure that you have connected both line back onto the tank ?

Matthew-Brisbane wrote:Are you sure that you have connected both line back onto the tank ?

Ahhh you have done that too Matt?

Not yet but i forgot to depresurise the line once 

Got a face full of fuel and petrol everywhere over the bike  

Was suprised by how much fuel is in the system even when the pump not running 

Could imagine what the result would be if the return side was left off and the pump kicked in

Three lines,
Front of tank down to fuel pressure regulator which is in between the airbox and throttle bodies.
From fuel pressure regulator and then on to the rear end of the injector rail by the coils.
From front of injector rail up to the fuel tank. This one should also have insulation on it.

You definitely need the bottom half of the airbox off to get at the fuel pressure regulator. It's got two Allen bolts down to the top of the engine and they can be well seized. Copper slip them before going back.

If you have the original clamps getting them off the fuel pressure regulator can be tricky, I used a junior hacksaw blade and elbow grease.

When you are putting new ones on, the two at the front of the tank make them about 1 1/2" longer and service/maintenance is much easier.

The old ones will be very stuck if original, treat the tank spigots with care as you could snap them. I used a scalpel to cut them.

For the new lines I got the fuel pipe connectors for the R bikes, not cheap but they are suitable and screw on and off. 6 of them but it means maintenance or emergency repair are much easier.

The regular fuel line cannot be used INSIDE the tank. But if you get fuel line that is suitable for immersion in the tank you can use of for both.

Best bet is get as much fuel out of the tank before you do the job. A few short lengths [4] of fuel hose, maybe about 1 1/2" long with one end plugged with silicone can act as a protective plug on the rail and tank spigots. Use new off cuts, old ones may shed crap into your system.

While you are looking under the tank clean up your earths that are bolted to the centre frame tube. Also be sure your fan is working properly, if not its a good time to sort that too.

RicK G wrote:

Matthew-Brisbane wrote:Are you sure that you have connected both line back onto the tank ?

Ahhh you have done that too Matt?

I didn't actually forget to put it on but was doing it blind with the lower still on and it didn't go on far enough. Fortunately the engine was cold but those pumps sure pump a heap of fuel.

renriv wrote:Have had fuel tank off on my K100RT and replaced the fuel supply line from tank to fuel rail, but now have fuel pouring out from middle of engine somewhere. Only place I can think of is the line to pressure regulator valve . The return line from fuel rail goes in behind air box above injectors so can't see in there. What is involved in getting to this valve ? I can't get any info from my manual to help me. Any help appreciated.
Allan

Reniv did you ever sort out the leak?

Yes did sort out the fuel leak. Posted on the original topic of poor spark ! turned out to be the return fuel line not clamped properly. Silly error but used the time while air off to degrease engine and clean up inside. All well now. Thanks