Modifying CBR600 fuel tap to suit VT250F-II

Parts that either fit a VTR 1 to 1 or can be easily modified to work.

Modifying CBR600 fuel tap to suit VT250F-II

Postby VTR250 » Fri Jan 05, 2018 11:12 pm

Okay folks, iv purchased a CBR600 fuel tap, in the hopes of making it fit my 88 VT250F-II (MC15).

I'm pleased to say (although it is still early days) that this is very doable with little work required. The plastic handle is abit to long, this will need to be shortened. I'll cut a section out of the middle, then place a sleeve over the cut section with araldite to hold it together, perhaps afew grub screws to relieve the twisting tension on the glue.

The vaccum port is coming out the front (this shouldnt be a problem) along with the fuel outlet and there is no strainer at the bottom (this, also, shouldn't be a problem. Using a inline fuel filter would give peice of mind)

It looks like I will need to remove a small amount of plastic from the heat shield, attached to the coil pack. The fuel tap looks to be touching slightly.

I will not be able to start modifying this tap until I have repaired the rust in the fuel tank and sealed it (takes 4 days :cry: ) This way, I can fit the fuel tap to the tank and make sure its not leaking before modifying anything.

I will update this thread as I progress.
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby Murdo1 » Sun Jan 07, 2018 12:45 am

Don't need the do a cut and shut of the tap handle. Take the screw out of the middle and if it fits replace with your old handle, or just trim some off the tap end of the handle and replace screw.
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby VTR250 » Sun Jan 07, 2018 2:08 am

I would be curious to see if the bikes orginal handle would fit the CBR fuel tap, but unfortunately, the fuel tap and handle was the only thing missing when I bought the bike. I have no choice but to use the CBR handle. I'll put some measurements up for information purposes
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby ExTex77 » Sun Jan 07, 2018 9:54 am

I measured the spare petcock's shaft as a square of 8.5mm
Not a perfect measurement but pretty accurate, enough to indicate that the petcocks use different handles.

You might try the handle from a 250cc Honda 4-wheeler (ATV). They look to be possible.
https://www.cheapcycleparts.com/oemparts/a/hon/52012757f87002346c9a1cc6/fuel-tank

Ride safely,
ExTex
1989 Honda VTR250 & 1988 Honda NT650
Wife rides a Burgman 200 scooter and I enjoy riding it also
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby VTR250 » Wed Jan 10, 2018 5:34 am

I did abit of work on this today. The side of the fuel tap was striking the drip tray and the position of the fuel outlet would have caused the fuel line to rub on the plastic.

IMG_20180109_202412.jpg


A little bit of plastic moulding and bending of the main bracket (the bracket attaching the coil packs to the frame of the bike) and iv got plenty of clearance for the the fuel tap and fuel line.

IMG_20180109_230106.jpg
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby VTR250 » Sat Jan 13, 2018 1:28 am

Next up, making that huge plastic disc, a little plastic disk. Placing the handle in your drill and holding it against a bench grinder works well for removing bulk of the plastic and keeping it nice and round. Hold it against sand paper to remove the burs, once you've reached your desired size.
IMG_20180113_190100.jpg
Shrinking disk


Once you've done this, you're going to need to shorten the handle, I removed about 10mm. Note, the handle shaft has a slight taper (smaller end attaches to the fuel tap, larger end is on the disk side) so make sure you cut it in a appropriate spot, depending on the ID of your pipe. (My ID was 13mm)
IMG_20180113_190714.jpg
Cut marks


Test fit it and remove any extra material, if you need to. Sliding a peice of pipe, the appropriate size, down the inside helps to keep things inline. Note, remove any burs, but leave the ends rough, this will help the glue to hold.
IMG_20180113_191519.jpg
Test fit


Once you are happy with the length, grab your peice of pipe and cut it to the appropriate length.
IMG_20180113_191957.jpg
Pipe cut


If you want to change the direction the arrow points, now is the time to do it. Mark what side the arrow needs to be on (iv chosen for the arrow to point up, this gives me room to place "on" an "res" labels on the hadle)
IMG_20180113_193123.jpg
Direction


Roughen up the edges with some sand paper to help the glue hold everything together and clean the inside of the pipe. Apply glue to the surfaces and press the ends into the pipe, making sure the arrow is pointing the same way as your mark.
IMG_20180113_194316.jpg
Glueing


Wipe off any excess glue and clamp in a vice. Let it cure and your all done!

Its in your best interest to use a decent glue (don't be the cheap guy) Iv used Sellys Araldite, rated to hold 150kg, it takes 3 days to fully cure, so be patient.
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby spotthedogg » Sat Jan 13, 2018 11:50 am

looks good, informative post!
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Re: Modifying CBR600 fuel tap to suit VT250F-II

Postby VTR250 » Sat Jan 13, 2018 3:33 pm

Cheers! I hope it proves to be useful for anyone struggling to find the original tap
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