Mercedes Mullins
The Honda PC800 is a popular motorcycle model, and many owners have shared their experiences repairing and modifying their bikes. One common issue is the fuel line, which can become damaged or clogged over time. In this article, we will explore the steps involved in repairing the fuel line on a PC800, including troubleshooting common problems, sourcing replacement parts, and performing the necessary maintenance to get your bike running smoothly again. We will also discuss some of the unique challenges and modifications that PC800 owners have encountered and share their solutions to help you tackle your own fuel line repair project with confidence.
| Characteristics | Values |
|---|---|
| Fuel line repair | Fixed the fuel return line |
| Fuel injection | Custom fuel injection system |
| Fuel gauge sensor | Remounted and leak-free |
| Fuel lines | Plumbed in to clear the stock air box |
| Fuel injectors | Fuel injectors and retention clips from VT1300C throttle body |
| Fuel leaks | None |
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What You'll Learn
Replacing the fuel tank, pump, fuel lines, and filter
To replace the fuel tank, pump, fuel lines, and filter on a PC800, you'll need to purchase the appropriate replacement parts, which are available from a variety of retailers. It's important to note that the process may vary slightly depending on the model and year of your PC800. Here's a step-by-step guide to help you through the process:
Firstly, locate and gain access to the fuel tank. This will involve removing any necessary panels or covers to expose the fuel tank and its connections. Make sure to place a container underneath to catch any spilled fuel. Once you have access to the fuel tank, you can start by disconnecting the fuel lines and any electrical connections associated with the fuel pump. It is important to clamp the fuel line before disconnecting it to prevent fuel spillage. Then, remove the fuel tank mounting hardware and carefully lift the tank out of the vehicle.
Next, you can replace the fuel pump. This will involve removing the old pump from the fuel tank and installing the new one. Ensure that you transfer any necessary components, such as the fuel level sensor, from the old pump to the new one. Secure the new fuel pump in place and reconnect the fuel lines and electrical connections.
Now, you can move on to replacing the fuel lines and filter. This process will vary depending on the specific routing of the fuel lines in your PC800. Carefully remove the old fuel lines, taking note of their routing and any clips or fasteners that hold them in place. Install the new fuel lines, ensuring they are securely fastened and routed correctly. The fuel filter is typically located along the fuel line, so you can replace it at this stage, ensuring the new filter is properly connected and secured.
Finally, reinstall the new fuel tank, ensuring it is securely mounted and all connections are tightened. Be sure to check for any leaks once the tank is installed and before starting the engine.
It is important to note that working with fuel systems can be dangerous, so it is always recommended to have a qualified mechanic perform these types of repairs if you are unsure or uncomfortable with any of the procedures. Additionally, ensure you are working in a well-ventilated area and take appropriate safety precautions when handling fuel and related components.
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Fixing the fuel return line
Firstly, it is important to understand the function of the fuel return line. On automotive fuel pumps, a return line is typically used to keep the fuel pump cool. However, in the case of the PC800, it has been suggested that the "fuel return line" is actually a vent line for the fuel pump. This discovery was made by referencing the VTX1300 Honda Fury's manual, where it is listed as a "fuel return vent line".
To fix the fuel return line, the vent line can be connected to an intake port within the airbox, similar to the crankcase breather hose. This allows the vent line to safely vent into the air that is being sucked in by the engine and burned in the combustion process. If the suction proves to be too strong and begins to suck up large amounts of gasoline, an alternative method is to dead-end the vent line into a small air filter located in the gas cap filler area. This allows for easy monitoring of the vent line.
Additionally, it is important to ensure that the airbox and air intake are not sucking up gas from the pump, as this can cause a mix of gasoline and oil to accumulate under the bike. To prevent this, a California-style gas cap with a hose barb can be used to plumb the vent line from the fuel pump.
Furthermore, adjustments to the air/fuel ratio on the PC800 carbs may be necessary. The factory settings are lean, and adjustments can be made by inserting small washers under the head of the needle jet to raise the needles. This will enrich the mixture by increasing the fuel delivered.
In some cases, choke needles may become stuck, and silicone lubricant can be applied to the metal stick under the knob to address this issue. It is also important to inspect the petcock, as fuel can leak down the vacuum line and into the intake if the rubber is damaged.
By following these steps and considerations, you can effectively fix the fuel return line on a PC800, ensuring the proper functioning of the fuel system.
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Adjusting the air/fuel ratio
It is important to note that adjusting the air/fuel ratio can be tricky, and extreme care should be taken during assembly. If you are uncomfortable with the process, it is recommended to seek assistance from a friend or a mechanic.
Additionally, before making any adjustments, it is crucial to inspect the bike for any underlying issues that may be causing problems. For example, the bike's low mileage may be due to a stuck air control valve or a vacuum problem, which can be caused by a loose or damaged rubber carb boot, or a missing cap on the nipple of the carburetor.
To further diagnose issues with the bike, it is recommended to take it for a ride and monitor its performance. You can also refer to the service manual for specific instructions and guidelines related to the PC800 model.
Once any underlying issues have been addressed, you can proceed with adjusting the air/fuel ratio by following the steps outlined earlier. Remember to exercise caution and make adjustments gradually to avoid any potential damage to the bike's engine or other components.
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Identifying and fixing fuel leaks
Step 1: Inspect for Leaks
Start by thoroughly inspecting your PC800 for any signs of fuel leaks. This includes checking the fuel lines, hoses, carburetor, and related components. Look for any cracks, damage, or loose connections that could be causing fuel to escape. A fuel leak can be challenging to locate, as evident in a case where a user noticed a strong gas smell but couldn't find any visible leaks for 1.5 years.
Step 2: Common Leak Locations
On the PC800, fuel leaks often occur due to worn or cracked fuel lines, particularly between the fuel pump and the carburetors. These hoses can become brittle and cracked over time, leading to leaks. Additionally, check the petcock, a fuel shut-off valve, as it is a common source of leaks on the PC800. The rubber in the petcock can leak fuel down the vacuum line and into the intake.
Step 3: Replace or Repair Leaking Components
Once you've identified the source of the fuel leak, it's time to replace or repair the faulty component. If a fuel line is cracked, replace it with a new, high-quality fuel-resistant hose. Ensure that all connections are secure and tight to prevent further leaks. In the case of the petcock, some users have opted to replace it with a simple metal or copper "T" pipe, effectively eliminating the potential for leaks from this component.
Step 4: Address Underlying Issues
Sometimes, fuel leaks can be symptomatic of underlying issues with the engine or fuel system. For example, a stuck air control valve or a vacuum problem could lead to inefficient fuel usage and potential leaks. Ensure that your PC800 is well-maintained and that all components are in good working order to reduce the likelihood of fuel leaks and other issues.
Step 5: Test and Verify
After making the necessary repairs or replacements, test your PC800 to ensure that the fuel leak has been resolved. Start the engine and carefully inspect all areas where leaks were previously identified. Ensure that all fuel lines, hoses, and connections are secure and free of leaks. Take the bike for a test ride and monitor for any unusual smells or signs of fuel leakage.
By following these steps and paying close attention to the specific characteristics of the PC800's fuel system, you can effectively identify and fix fuel leaks, ensuring the safe and efficient operation of your motorcycle.
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Synchronising the carbs
Firstly, it is important to understand the role of the carbs (carburettors) in the Honda PC800's fuel system. The carbs are responsible for mixing air and fuel in the correct proportions to ensure efficient engine performance. Over time, the carbs can fall out of sync, leading to poor fuel mileage, backfiring, and stalling issues.
To synchronise the carbs, begin by locating the inspection lids on the carbs. These lids provide access to the gas mixture screws and choke needles. Before making any adjustments, ensure that the engine is turned off and the carbs are cool to the touch. Using a suitable tool, gently turn the gas mixture screws on each carb to adjust the fuel-air mixture. The screws can usually be turned up to 3/4 of a turn to richen the mixture. Be cautious not to overtighten the screws as this can damage the seats.
In some cases, the tabs or tabbed covers on the gas mixture screws may have been removed. If this is the case, gently turn the screws inwards and then open them by 2 and 1/2 turns on each carb. The fuel level can be affected by factors such as fuel temperature and electricity gauge readings, so it is important to refer to the manufacturer's guidelines or seek advice from a qualified mechanic.
Additionally, pay attention to the choke needles. In some instances, they may become stuck or difficult to remove. Apply a small amount of silicone lubricant to the metal stick under the knob to ease the movement of the choke needle. Check the right-side plastic ring, as it can be tricky to reach and tighten.
Finally, refer to the manufacturer's service manual for specific guidelines on float height adjustment. A common method is to use a clear hose or pipe on the drain below the carb to inspect the float height. Adjust the floats accordingly to ensure they are at the correct height.
By carefully following these steps, you can effectively synchronise the carbs on your Honda PC800, improving its performance and fuel efficiency.
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Frequently asked questions
To repair a fuel leak, you should check the vacuum hose for the automated petcock. If the rubber is damaged, it could be leaking fuel down the vacuum line. You should also check the air control valves and the air control valve fixed.
The fuel delivery on the PC800 carbs is controlled by the jets. The needle is adjusted by inserting small washers under the head of the needle jet.
The fuel return line on the PC800 is actually a vent line for the fuel pump. You can connect the vent line to an intake port in the air box.
You can use a heavy-duty carb cleaner to clean the fuel lines.
You can use JB Weld to secure the fuel lines.
