Warning, Disconnect the battery before doing this Modification. This may also void your manufactures warranty. Be sure to do this modification in a well ventilated area.

 After much dispute over fuel levels and when does the 250X run empty on fuel, I ordered up a new 250X fuel tank along with a R&D deep fuel pickup to test the results of what is really going on.

 Let’s start with a list of stuff used and for what.

3ft level to ensure fuel tank was level.

A new Jet Ski Stand with casters to hold tank and allow for movement to see sloshing effect.

A 5 gal fuel jug and siphon hose.

Brand new 250X fuel tank.

My stock pick-up unit.

R&D deep fuel pick up.

Starting with a new tank I cut open the top. Notice the thickness of the fuel cell wall…

I then installed the sending unit from my stock tank into the new test tank. Installing it as it sits in the stock tank. I then ran jumper wires from the stock plug the the fuel tank sending unit. Filling the tank with fuel until my low fuel buzzer turned off. Marking Tank.

That’s when I started draining fuel out of the tank using the stock pick up. Once bubbles started to be sucked up I marked the stock empty point. I then installed the fuel pick up and continued to drain the tank using the R&D fuel pick up. Once again marking the empty point.

Result’s? Buzzer went off at almost 7 gallons when sloshing. 5.5 when still and level. Stock empty with 2 gallons left and empty at 1.25 gallons left on the R&D fuel pick up.

OK so testing was fun but now lets get into the install and mod stuff.
I followed the R&D instructions closely.

Here are some pointers. Use a rag under fuel line when removing it because fuel will leak out of it. Unhook the reverse cable from behind when moving center dash aside and use a sharpie to mark point on can of white plug.

Carefully continue to remove per R&D instruction sheet.

Installing the billet pick-up was not easy. I had to use a rubber mallet to seat it correctly.

 

 So I got this far and decided to make a bit of adjustment. Notice the stock setting of the fuel pick-up . White plug on fuel pick-up lines up with black marking.

 What this does is allow the pick-up to rest in the center of tank where it is deepest.

I then bent the float arm to rest 1.5 inches lower in tank. Best if you lay the assembly on table then bend the float arm to obtain the 1.5 inch drop in the resting empty position.

I then reinstalled the fuel pick-up unit. Testing the fuel buzzer now sounds at 3 gallons left. Even during sloshing the tank. The V-shape of the tank help maintain the float pretty well. Leaving only 1.5 or so gallons to get more fuel.

Oh and for those who want to try a “fuel clunk”. It does seem possible but not to sure as to how it would mount securely to the fuel pump.

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UPDATE UPDATE UPDATE!!!!!!!!!!!!!

This morning I received a call from R&D Performance. Glen has been following our efforts with the 250X. He seems to be a fan of our work and has offered to help us get testing correct. His input has been valued in the past and will be looked to in the future.

Well in our conversation he commented on the Tank Test. He complimented our efforts and said it was a good write up. He then went on to explain how we missed a major and crucial aspect of our testing.

As he explained, R&D worked for some time testing this mod with the assistance of Factory Kawasaki. It was much more then a level bench testing as I had done. It was testing of actual watercraft moving forward in the water which makes the nose rise. This rise allows the fuel to collect in the rear section of the tank where the fuel pick up rests. Its this collection that allows more of the fuel to be utilized by the R&D fuel pick up mod.

We also talked of my modification to allow the fuel lever arm to trigger lower in the tank. Well by doing my mod it would work for the sensor but compromise the pick up of fully utilizing all the fuel it can reach. So we concluded that I should move the pick-up unit back to the stock setting but bend the fuel level arm 30 degrees to center tank. This is not a recommended modification but will I will be trying it to see if this IDEA works.

The only way to accurately test this small part would be to have this modification on during riding, running as much fuel as possible out of the tank, to see how much could be used before completely running out. This is running a risk of possibly running the engine lean. Something that I personal am not willing to try on my own. I’m sure R&D has a much larger resource for potential issues during their real world testing. Ive concluded that I’ll take Glens word on this one.

Regardless this outstanding display of respect and professionalism was awesome and we are so glad that Glen took time to help us get it right. Glen could have easily been upset with us and boasted his massive accomplishment to down our humble efforts but instead he offered a gentle and knowledgeable helping hand. This helps ensure Project 250X gets it correct and in return helps the Ultra community grow with solid knowledge.

Thank You so much Glen with R&D.

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