2003 EV Fuel system

[drdwb]

I need help figuring out how the fuel lines run to the tank and pressure relief valve of a 2003 EV, it has the external fuel pump and fuel filter, and manual petcock, so it’s one of those between models Guzzi did to use up existing parts before converting everything to the new next years models. I’ve looked through my parts, and shop/ service manual but the diagrams/ illustrations all show the set up for the internal pump and filter, and don’t show a pressure regulator under the top front part of the tank.
I replaced all the rubber hoses a couple years ago when I was dealing with the tank leak. Now The pressure in the tank gets so high when sitting for a couple days that I’ve had to leave the cap loose, or it’s difficult to remove the gas cap ( no ethanol fuel used) and the fumes in the garage are very bad, even with the cap off. I took apart the regulator and cleaned it but didn’t help. So I’m thinking I probably ran the lines wrong and it’s kinking the one of the lines either connecting to the tank or regulator or the vent line.

If anyone has a shop diagram / reference, pictures or has experience with this set up I would sure like your help.
Thanks
Dave

So what I’m asking for is help with the proper connections to the tank, regulator, vent, and line placement. The pictures show the set up.

[Tom H]

My '04 uses the internal pump, I'm pretty sure that the '03 did as well.

I'm guessing here that the tank you have is from an earlier year, something like a maybe a '98ish EV? Normally the pressure regulator would be mounted in the frame near the coils and a hose run up to the front of the tank. It would not be screwed onto the tank.

The hose barb next to the regulator is the vent if you didn't already know that.

Tom

[guzzisteve]

That set-up is in the service manuals with diagrams, look up for 02 model.

2nd book in index on left table   Section "I" page 4 & 5

https://www.guzzitek.org/atelier/gb/1100/California1100_Atelier_Compil.pdf

[michaell32]

I don't see anything about vent lines but my guess would be that the nipple off the tank is supposed to run to the air box.  If that is plugged it would explain the tank pressure.  The regulator doesn't seem to have a vacuum reference.

[guzzisteve]

The vent line is nipple next to fuel return which is the pressure regulator. Mine goes to outside air.
Stock it would have a check valve in line then go to EVAP canister.

[Wayne Orwig]

The small connection in the center of the tank is the water drain for the fill cap. It just drains to the ground. (obviously don't ignore or gasoline spills will go on top of a hot motor)
The small tank connection near the regulator is the vent. It normally goes to a tip over valve, a one way valve, then the charcoal canisters.
The small connection on the pressure regulator is left open as is.

The fuel lines are covered in the picture above.
Do NOT plug the low fuel light into the wrong connector (if you have the other connector) or it can be burned out quickly.

[drdwb]

Thanks all for the reply’s. If I am following correctly the line connected to the vent nipple next to the regulator at the top of the tank is where my line takes a very severe bend and kinks, I understand it would have run to a check valve and than the canister. Should/ does that line have to go back to where it would go after the canister? Where it does currently? Or can I just run a line from the vent to below the frame and let it drain there?
I would suppose the purpose of the check valve is to prevent gas from spilling out if the bike tips over, the canister is just pollution control stuff and the line from the back of the canister goes into the crank case. So that line should be plugged?
Currently I’m assuming ( it looks like) the line coming from the vent goes to where the line that would come from the back of the canister goes to the case. I have no canister. But I definitely have a problem with high tank pressure due to this kink, I hope.

[Wayne Orwig]

If you have no canister, run it away from the hot exhaust to the ground. Most of those type drains are routed to the back of the transmission where there is a metal bracket attached to the transmission near the shift linkage to hold them.

[BMCMOTO]

Because these vent tubes are small and made of steel, it is sometimes worth the time to ensure that they are completely open. In that interest, I typically run something through them, bicycle control cable works, motocycle control cables work too. I have been amazed at the crap found there.

Brian