Fuel rail fix!!! MSX 110
Hello. Well I called everyone and they all told me the same thing. Good luck finding a fuel rail..... I even called Polaris directly and they said the same thing. So what to do with a PWC with a $40 part thats broke and cant find a replacement. I love to make things work so what I did was fix it.
(1) I took the fuel rail off and both injectors.
(2) I then ground down the busted nipple male off the fuel rail and hollowed it out just a little to fit the fuel nut I found in part 4.
(3) I cleaned it up inside and out
(4) I had a few extra carburetors laying around in my garage from my previous race history. one was a holly 750 double pumper and other was an original thermalquad four barrel. Where you screw in the fuel line to the carb is the part I used. I found the thermalquad threads and nut size to be much better then the holly. the holly is a little to big but works.
(5) I cleaned up the fuel nut really well. you don't want dirty parts! Its a must for clean parts.
(6) I checked the hole I made with the threads of the fule nut. You want it to almost fit. DONT MAKE IT TO BIG! Make it to where it cant thread in but sits on top of the hole.
(7) I then put the nut into a set of vice grips
(8) I heated up the nut to almost red temperature
(9) I then forced the fuel rail onto the threaded part of the fuel nut
(10) I then dipped the rail with the nut into luke warm water. After the fuel nut made it in you much cool it ASAP or it will keep melting the plastic causing a bad seal.
(11) After it cooled down I put JB Weld around the nut for extra seal and support. I found mine held air just from the plastic welding fast to the nut but that little extra never hurts.
(12) Get yourself some standard metal fuel line at any auto parts store. you only need about 3-6 inches of metal line and cut the rest off. I think it is 5/16ths
(13) Also get some rubber O rings! You will need to put the rubber O ring into the fuel nut then screw the metal line in.
(14) Install the metal line on the fuel rail before installing. I do this so there is less stress on the rail and space. Most importantly less stress on you because space can get tight.
(15) install everything and hook your rubber fuel line onto the metal fuel line. Yes you will need to cut off them push on caps on the stock rubber line. Also use 2 fuel claps! Extra security never hurt. Use only name brand good quality clamps!!!! I tried cheap ones and they broke when tightening them just a little bit.