Might need some help putting my '01 back together again.

I took my '01 apart 3 years ago to do some deep cleaning and minor sprucing up. I'm one of those doesn't know when to stop and keeps going whenever they see something, and before you know it you have basically a frame with an engine left!

In my case I removed everything from the frame apart for the engine and the front forks. Plastics, tank, seat rear wheel, rear swing arm, rear shock all were removed.

Life events got in the way, plus having another bike to ride, meant that the project really stalled out. I have finally taken on enough enthusiasm, mixed with equal parts of shame, to really tackle the rebuild and get the bike back on the road again.

Aside from thoroughly cleaning every part removed, the following work has been done so far:

Seat recovered and new foam

New chain

New front sprocket

New rear sprocket

Spark plugs replaced

Air filter replaced

Engine oil and filter change

Clutch completely flushed with new fluid

Rear axle cleaned and greased

New thermostat

New O rings on the T-stat housing

New O rings on the coolant hoses connected to the cylinders

New O rings on the water pump (cover and drive shaft).

I have refitted the rear shock, swing arm and wheel.

Rear subframe back on the bike and rear panels fitted.

Coolant pipes and radiators refitted.

Getting ready to deal with the nightmare of installing the throttle body unit.

Before I do that I have a hose that needs to be replaced. The rubber is in bad shape and there is a gash in it. I need to identify the hose so I know what to order, but I am also not sure where either end of this hose attaches to. This hose is pictured and is somewhat unique because at one end is an angled T-piece.

Any help is much appreciated!

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Is that the tank overflow with the angled joiner? If so, that runs inside the R frame spar by the rear head, then along the top of the clutch cover, then around the front of the motor and terminates in the bracket near the sidestand, so that all the fuel that you overflow doesn't run onto the header pipe! 

if you grab the service manual, all the hose runs are shown in the first section. 

16 minutes ago, Terry

Is that the tank overflow with the angled joiner? If so, that runs inside the R frame spar by the rear head, then along the top of the clutch cover, then around the front of the motor and terminates in the bracket near the sidestand, so that all the fuel that you overflow doesn't run onto the header pipe! 

if you grab the service manual, all the hose runs are shown in the first section. 

Thanks, Terry!

That sounds feasible. I will follow that idea and look in my SM.

It's been so long that my memory is no help any longer, and I forgot to label the parts! 🫤 I know better than that now.

And the "Parts Not Available" fun begins.

That fuel tank hose is 17544-MBG-000 and is not available from the big parts sites I have checked so far. 

The funny thing is that I don't think my hose is OEM. It is supposed to have a 90' bend near the end, whereas mine is straight, making me think mine was a non-OEM replacement to begin with. Seems like the easy fix is to find the correct diameter rubber tubing and make my own replacement hose.

I would not be too hung up getting that specific hose right; it is just an overflow, so not in regular contact with fuel, and likely to get rinsed through with water in rain or if you wash your bike. Pretty sure I just went with fuel-compatible hose of the right ID at an auto-parts store. 

My '98 is apart on the way to reassembly... .Here's photo of the 4 hoses I have for the tank...

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The "while you're there" syndrome.  Or "Now is the time to do it, everything is out of the way."

Been there way too many times.  All of a sudden it's a frame, an engine and a limp wire harness hanging from each end. 

But it feels so good when it starts going back together and getting "big" again. 

Nice!! 

Is this mounted correctly to the plastic undertray? 

It seems really tight against the tank bracket.

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21 hours ago, davenay67

Is this mounted correctly to the plastic undertray? 

It seems really tight against the tank bracket.

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Nearly but no cigar.

Spin it 180 & it's correct 👍

5 hours ago, Gaz66

Nearly but no cigar.

Spin it 180 & it's correct 👍

Not what I was wanting to hear, but I appreciate the input. 🙂

The wiring seems really tight, and I'm not sure turning 180 degrees is going to be all that easy. Might need to find what is preventing that....

Update: Actually quite easy once I removed the tank bracket and unplugged the top cable.

Much better.

Hang on... Mine's apart... I'll get a photo of mine and post it tomorrow.

18 minutes ago, mello dude

Hang on... Mine's apart... I'll get a photo of mine and post it tomorrow.

Keep it apart....I'm sure to run into many other 'how does it go back?' questions. 🤣

21 hours ago, davenay67

Not what I was wanting to hear, but I appreciate the input. 🙂

The wiring seems really tight, and I'm not sure turning 180 degrees is going to be all that easy. Might need to find what is preventing that....

Update: Actually quite easy once I removed the tank bracket and unplugged the top cable.

Much better.

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Single Fuse holder above⬆is upside down.

Did u inspect the female terminals in the plug?

Prone to becoming loose when plugs been off a few times, causes a weak connection/high resistance, terminals lose their springiness & don't grab the male terminals in the relay enough, replaced loads of melt down plugs & relays, often cooks the loom making wiring stiffer than a porn stars 🐓 which needs cutting out & replacing too.

If plug's good it's worth squeezing females back together with a small straight bladed driver for a snug fit onto males.

New plug/terminal kits are available as a pattern part should the need arise, I always keep a few in stock for customers.👍

Photos... Hope this helps!

Rubber shield and Tank Bracket.. 

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Starter Solenoid Circuit

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Btw - You miight review my thread on Thermostat/hoses/brakes for ideas

New throttle body intake rubbers ordered. 

I'm really starting to get excited that I can finish the VFR and be back on the road for the '26 riding season. 

Throttle body is cleaned and ready to mount when the new intake rubbers arrive.

Air cleaner is cleaned and read to fit as well. I seem to recall buying a new air filter, but I'm having trouble finding it. No doubt as soon as I buy another the original will mysteriously appear again.

It's been apart long enough that I feel I need to pull the fuel pump and inspect everything for good measure. Dump all the old gas at a bare minimum.

The bottom of the fairing took a big hit at some point during the PO's ownership. I have repaired the damage structurally, but over the winter is a good time to paint the repair as well.