WHAT CONSUMERS NEED TO KNOW: Changes in Fuel System Components and Yamaha s New Fuel System Connectors
As a result of new EPA regulations, changes to portable marine fuel tanks, fuel hoses and primer bulbs will soon affect boat builders, marine dealers and consumers. Consumers should become familiar with the changes in the system components and their operation. They should also become aware of a new Yamaha-exclusive fuel line connector. THE NEW FUEL SYSTEM COMPONENTS Portable Tanks, Fuel Hoses and Primer Bulbs will Change Tanks Now Pressurized In addition to the use of low-permeation fuel hose, required since 2009, new boats will soon be using low-permeation primer bulbs (effective January 1, 2011). For boats that use portable fuel tanks, new tanks must now meet both low-permeation and evaporative emissions standards (effective January 1, 2011). This requires, in part, that the fuel system (tank, lines, and components) be sealed, which may cause them to become pressurized. New portable fuel tanks are made of material that reduces permeation. On the new tanks, the fuel filler cap will not permit uncontrolled venting of fuel vapor to the atmosphere. Fuel vapor, when not allowed to vent to the atmosphere, will create pressure inside the tank. The fuel cap in these new
tanks remains sealed up to five psi before allowing the vent to open and reduce internal pressure. Fuel caps are made of a low-permeation material and are equipped with valves that keep fuel vapors from escaping until a pre-set pressure is reached. Also, new low-permeation tank material used in the construction of the fuel tank and cap assembly is certified to reduce hydrocarbon loss during daily temperature swings (for tanks with production dates of 1/1/2011 and later). New products affected by the regulation are 3.1-gallon (12L) and 6.6-gallon (25L) portable fuel tanks, which are applicable to all Yamaha F4A through F70LA models. Production of these new tanks is scheduled to begin in April 2011. YAMAHA S EXCLUSIVE NEW CONNECTORS Fuel Tank Regulation Inspires New Hose Connectors Designed to Reduce Fuel Spills, Spray Apart from supplying new components that meet the regulations, Yamaha has engineered additional features into its fuel line connectors that are intended to be used with the new fuel system components. With ease of use and security in mind, these new fuel line connectors now found on Fuel lines sold by Yamaha will also use the company s unique fuel line connector.
Yamaha outboards, portable fuel tanks, and hoses are different from those traditionally used in the industry. Yamaha s new fuel line connectors will employ a twist-on locking design to create a seal before permitting fuel flow when connecting or disconnecting. This feature helps reduce the potential for fuel spray or leakage when the fuel line is removed or installed. The Yamaha-specific connectors are found on both the outboard side and the tank side of the new Yamaha fuel lines. WHAT THE CHANGES MEAN Your Dealer Will Need to Match Components and Assure Compatibility These portable fuel tank systems will be accompanied by instructions that outline the correct methods of tank operation. Dealers should ensure correct (matching) components are installed in the fuel system prior to delivery, and the end user should become familiar with these new components and procedures upon delivery and before leaving the dealership. The owner s manual accompanying Yamaha outboards with newstyle connectors provides instructions outlining the correct usage of the new fuel tanks and fuel connectors. New-style fuel tanks sold by Yamaha will use the company s unique fuel line connector that reduces the occurance of spraying.
NOTE: EPA regulations allow manufacturers and dealers to deplete existing inventories of non-compliant portable fuel tanks. Yamaha will change from original-style engine and fuel hose connectors to the newstyle connectors as the inventory of non-compliant fuel tanks is depleted. NOTE: Tampering with new compliant products to limit their abilities to reduce emissions as designed is against federal anti-tampering regulations and subject to penalties. Yamaha strongly discourages retrofitting new components with old-style components. The fuel hose and primer bulb assembly shown above has the new Yamaha connectors. NOTE: At the time of publishing, the new-style fuel tanks had not been approved by the California Air Resources Board (C.A.R.B. ) and thus are not for sale in the State of California. FREQUENTLY ASKED QUESTIONS Q. Will all Yamaha F4A F70LA outboards require a compliant portable fuel tank after 1/1/2011? A. Not necessarily, for two reasons: 1. Motors produced prior to the start of fuel tank compliance (1/1/2011) can be used with non compliant tanks. 2. The EPA regulations allow manufacturers and suppliers to deplete existing inventory based on their typical ordering/inventory cycle.
Q. Can an older outboard with an original-style fuel connector on the engine side be used with the new compliant fuel tank? A. Yes, the original-style fuel connector on the motor can be replaced with a new-style connector to allow use of a new, compliant fuel tank. Yamaha encourages that this be done for older outboards produced prior to 1/1/2011 when a replacement fuel tank or hose assembly is required. Q. Can dealers or boat builders repair compliant portable fuel hose assemblies with new-style connectors? A. Yes, compliant components are available individually. Yamaha recommends that all hose-to-barb connections must be sealed with 360 - contact, crimp-style clamps, such as an Oetiker clamp, and be installed in compliance with ABYC H25. Q. Can an outboard with a new-style connector or fuel hose be used with an old-style tank and/or connections? A. No. Yamaha strongly discourages altering new-style, compliant engine fittings, hoses, or portable tanks for use on, or with, old-style fittings, hose or portable tank(s). Furthermore, replacing a compliant component with a non-compliant component could be a violation of Federal anti-tampering laws and subject to penalties. Q. Can non-compliant portable fuel tanks be repaired using old-style components? A. Non-compliant tanks and fuel hose assemblies should be replaced with compliant components when replacement is necessary.
Q. Can a consumer buy a non-compliant Yamaha portable fuel tank to use with an older motor? A. Yes, but only until inventories of tanks manufactured prior to 1/1/2011 are depleted. Q. Are there any precautions when servicing a fuel system that uses new components? A. Yes. Always de-pressurize the fuel system prior to any service work, including replacement of fuel filters. Instructions are included with the tank assembly. Q. Can new-style, low-permeation fuel hoses be used with hose-to-barb connections? A. Yes, but great care must be used. Some aftermarket, emissionscompliant hoses contain a special inner liner to prevent permeation that can inadvertently be damaged when installed on barbtype connections. Use caution when routing to prevent chaffing, and do not over-tighten hose clamps. Yamaha recommends that fuel line connections should be sealed with 360 -contact, crimp-style clamps, such as an Oetiker clamp. Clamps must be installed in accordance with ABYC H24 on permanently installed systems or H25 on portable fuel systems. This document contains many of Yamaha s valuable trademarks. It may also contain trademarks belonging to other companies. Any references to other companies or their products are for identification purposes only, and are not intended to be an endorsement. Materials contained are intended to be used for general educational and informational purposes only. You are encouraged to seek the services of a qualified professional before utilizing or relying upon any information presented herein. While every effort has been made to ensure such accuracy of the information contained herein, Yamaha Motor Corporation U.S.A. does not guarantee such accuracy, correctness, reliability or completeness of the information or anything related directly or indirectly to the use of this information in any way, and can t be held liable for any errors in or any reliance upon this information. For information on boat safety best practices, visit the United States Coast Guard website at www.uscg.mil. April 2011, Yamaha Motor Corporation, U.S.A. All rights reserved.
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