Super Jet Internal fill/front fuel pickup mod with no cutting of the tank. How to.

[Req]

I decided I wanted to do internal fill on my superjet however was wary of cutting on an otherwise stock tank. After seeing Waxheads front fuel pickup for 550 Kawasakis I thought I may be able to emulate something like that for cheap. This method does not require any cutting. Tank manufacturing differences may cause fitment issues however my new stock superjet tank had perfect fitment.

You will need:

Yamaha filler cap assembly


90 degree fuel pickup WPS-12-7250 ($12.50)


Fuel filter/clunk WPS-12-7312 ($7.00)


Schedule 80 1.5" cap ($1.88)
https://www.lowes.com/pd/CARLON-1-1-2-in-PVC-Cap/3461182

Small section of 2" fuel fill hose

1 extra 2" hose clamp

Start by removing the small lip on the fuel fill cap flange. Make it flush with the rest of the housing. This will allow it to slide down in the fuel pickup location. Additionally drill a 1/2" hole opposite the chain tether to allow for fuel to fill up to near the top of the tank without overflowing.



Next you will drill a 1/2" hole in the center of the PVC cap. This will allow for the fuel pickup fitting to be installed in the cap. Put the rubber grommet in the 1/2 hole then press the fitting into place. Cut a section of fuel line that will reach to the bottom of the tank and attach it and the fuel clunk to the barb on the inside of the cap.



Next you will take you 2" diameter fuel fill hose and cut it to about 3" long. Affix the hose to both the tank and the fuel pickup with hose clamps. The cap side will require a small amount of stretching but it is manageable.



Now if you tank is anything like mine with the lip removed the fuel fill cap should slide down in about perfectly. With a hose clamp I have a perfect seal. Due to manufacturing differences your results may vary. If the seal is loose you may need some oil resistant gasket maker to seal the leak.







Good luck!