Introduction
This instruction manual provides detailed guidance for the proper installation and maintenance of the AER MOTO SPARE PARTS Fuel Tap Repair Kit. This kit is specifically designed for Yamaha XTZ Super Tenere 750 motorcycles manufactured between 1989 and 1992. Following these instructions will help ensure the correct function and longevity of your motorcycle's fuel tap after repair.
Safety Information
Always prioritize safety when working on your motorcycle. Fuel is highly flammable and its vapors are explosive. Ensure you are working in a well-ventilated area, away from open flames, sparks, or any ignition sources. Wear appropriate personal protective equipment, including gloves and eye protection. If you are unsure about any step, consult a qualified mechanic.
- Disconnect the battery before starting any electrical work.
- Ensure the engine is cool before handling fuel components.
- Have a fire extinguisher readily available.
- Dispose of old fuel and parts responsibly according to local regulations.
Kit Contents
Before beginning the repair, verify that all components listed below and shown in the image are present in your kit.
Figure 1: Fuel Tap Repair Kit Components. This image displays the complete contents of the fuel tap repair kit. It includes a circular O-ring, a rectangular gasket, two larger hex-head screws, and two smaller Phillips-head screws. Also visible is a black plastic or rubber component with multiple holes, likely another gasket or diaphragm. In the background, a business card for N.C.D.M. 2000 s.a.s. provides contact details and a QR code.
- 1x Circular O-ring (for main body seal)
- 1x Rectangular Gasket (for fuel tap cover)
- 1x Multi-hole Diaphragm/Gasket (black, for internal mechanism)
- 2x Hex-head Screws (larger, for mounting)
- 2x Phillips-head Screws (smaller, for cover)
Setup and Installation
This section outlines the steps for disassembling the old fuel tap and installing the new repair kit components. Refer to your motorcycle's service manual for specific torque specifications and additional details.
Tools Required:
- Screwdrivers (Phillips and appropriate hex/socket)
- Pliers
- Drain pan for fuel
- Clean rags
- Torque wrench (recommended)
Installation Steps:
- Fuel Drainage: Ensure the fuel tank is nearly empty or drain the fuel into a suitable container. Turn the fuel tap to the "OFF" position.
- Remove Fuel Lines: Carefully disconnect all fuel lines connected to the fuel tap. Be prepared for residual fuel to leak.
- Remove Fuel Tap: Unscrew the mounting screws (likely the larger hex-head screws if applicable to mounting) that secure the fuel tap to the fuel tank or frame. Remove the entire fuel tap assembly.
- Disassemble Fuel Tap: On a clean workbench, carefully disassemble the fuel tap. This typically involves removing the smaller Phillips-head screws that hold the cover plate. Note the orientation and position of all internal components, especially the diaphragm and gaskets.
- Clean Components: Thoroughly clean all metal parts of the fuel tap body. Remove any old gasket material, dirt, or fuel residue. Inspect for corrosion or damage.
- Install New Components:
- Place the new multi-hole diaphragm/gasket in its correct position within the fuel tap body.
- Install the new rectangular gasket onto the cover plate or fuel tap body, ensuring it aligns with the screw holes.
- Carefully reassemble the fuel tap cover, securing it with the new smaller Phillips-head screws. Tighten them evenly.
- Replace the circular O-ring on the main body of the fuel tap where it seals against the fuel tank or mounting surface.
- Reinstall Fuel Tap: Mount the repaired fuel tap back onto the motorcycle, securing it with the new larger hex-head screws. Tighten to the manufacturer's specified torque.
- Reconnect Fuel Lines: Reattach all fuel lines securely. Ensure all clamps are tight.
- Leak Check: Refill the fuel tank. Turn the fuel tap to the "ON" position and carefully inspect for any fuel leaks around the fuel tap and connections. Address any leaks immediately before operating the motorcycle.
Operating the Repaired Fuel Tap
After successful installation of the repair kit, the fuel tap should function as originally designed. Ensure you understand the positions of your fuel tap:
- ON: Allows fuel flow to the carburetor. Use for normal riding.
- RES (Reserve): Accesses the lower portion of the fuel tank. Use when the main fuel supply runs low.
- OFF: Stops fuel flow. Always turn to OFF when parking the motorcycle for extended periods to prevent carburetor flooding or fuel leaks.
- PRI (Prime - if applicable): Bypasses the vacuum system to allow fuel to flow directly to the carburetor for starting after maintenance or if the fuel system has run dry.
Maintenance
Proper maintenance ensures the longevity of your repaired fuel tap and prevents future issues.
- Regular Inspection: Periodically check the fuel tap for any signs of leaks, especially around the gaskets and connections.
- Fuel Quality: Use clean, high-quality fuel to prevent contaminants from clogging the fuel tap or damaging internal components.
- Storage: When storing the motorcycle for extended periods, turn the fuel tap to the "OFF" position and consider draining the carburetor float bowls to prevent fuel degradation and gumming.
Troubleshooting
If you encounter issues after installing the repair kit, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Fuel Leak from Tap | Improperly seated gasket/O-ring, damaged new component, loose screws. | Recheck gasket/O-ring placement, ensure screws are tightened evenly and to spec. Inspect new components for defects. |
| No Fuel Flow | Fuel tap in "OFF" position, clogged fuel filter, vacuum line issue (if vacuum-operated tap), incorrect diaphragm installation. | Ensure tap is "ON" or "RES". Check fuel filter. Verify vacuum line connection. Re-examine diaphragm installation. |
| Intermittent Fuel Flow | Partial clog in fuel tap or lines, vent hose blockage. | Clean fuel tap internals thoroughly. Check fuel lines and tank vent for blockages. |
Specifications
Key specifications for the AER MOTO SPARE PARTS Fuel Tap Repair Kit and its application:
- Brand: AER MOTO SPARE PARTS
- Vehicle Service Type: Yamaha XTZ Super Tenere 750
- Applicable Years: 1989, 1990, 1991, 1992
- Fit Type: Vehicle Specific Fit
- Material (Kit Components): Plastic or Metal (gaskets, O-rings, screws)
- Body Material (Original Tap): Aluminum (as per product spec)
- Gas Type: Gasoline
- Mounting Type: Tank Mount
- ASIN: B082YG3V97
Warranty Information
Specific warranty details for this AER MOTO SPARE PARTS product are not provided in this manual. Please refer to the product packaging or contact the manufacturer/seller directly for warranty terms and conditions.
Support and Contact
For technical assistance or inquiries regarding your AER MOTO SPARE PARTS Fuel Tap Repair Kit, you may contact the distributor:
N.C.D.M. 2000 s.a.s.di Antonio Di Fiore
Via Travi, 8 (Palazzo Di Fiore)
80040 CERCOLA (NA), Italy
Phone: +39 081 733 38 39 / +39 081 733 11 70
Telefax: +39 081 555 09 62
Email: ncdm2000@virgilio.it, info@ncdmricambimoto.it
PEC: ncdm2000sas@legalmail.it
Website: ncdmricambimoto.it
Fiscal Code / VAT ID: C.F. - P.I. 02841601210
SDI: 5RUO82D
