10 Gallon Kit

Park the machine on a level surface, shut off the engine, chock the wheels, disconnect the battery, and remove the key.

Allow the engine to cool, then drain the fuel tank into a fuel container using a pump.

Note: Dispose of fuel properly. Recycle according to local codes.

Start the engine and run it until it stops.

Choke the engine. Start and run the engine until it does not start.

Disconnect the fuel tank hoses from the machine and discard them (Figure 1).

Note: Retain the hose clamps.

Remove the fasteners and straps securing the fuel tank to the machine and discard them along with the tank (Figure 1).

Disconnect the remaining hoses from the carbon canister (Figure 1).

Note: Retain the hose clamps.

Remove the battery cover and battery (Figure 1); refer to your Operator’s Manual.

Remove the carbon canister and discard it (Figure 1).

Figure 1

1. Battery cover
2. Carbon canister
3. Fuel-tank hoses
4. Fuel tank

Remove the existing fuel-tank mount and install the new 10 gallon tank mount using 4 carriage bolts (5/16 inch) and 4 flange nuts (5/16 inch) through the holes in the tray as shown in Figure 2.

Figure 2

1. Flange nut (5/16 inch)
2. Existing fuel-tank mount
3. Fuel tank tray
4. Carriage bolt (5/16 inch)

Install the fuel tank mount as shown in Figure 3.

Figure 3

1. Fuel-tank mount
2. Fuel tank tray
3. Bolt (5/16 inch)
4. Nut (5/16 inch)

Attach the carbon-canister bracket to the frame using 2 bolts (1/4 inch) and 2 flange nuts (1/4 inch) as shown in Figure 4.

Note: If the bracket does not perfectly line up with the existing holes, widen them slightly using a 7 mm drill bit.

Figure 4

1. Flange nut (1/4 inch)
2. Carbon-canister bracket
3. Bolt (1/4 inch)

Secure the carbon canister to the bracket using the canister strap and 2 carriage bolts and flange nuts (3/8 inch) as shown in Figure 5.

Figure 5

1. Bracket
2. Flange nut (3/8 inch)
3. Carriage bolt
4. Canister strap
5. Carbon canister

Attach the pads to the fuel-tank straps (Figure 6).

Figure 6

1. New fuel-tank straps
2. Pad
3. New fuel tank
4. Flange nut (1/4 inch)

Secure the new fuel tank to the fuel-tank tray using the straps and 4 flange nuts (1/4 inch) as shown in Figure 6.

Attach the hose adapter and short hose to the inline fuel filter and secure it to the bottom of the carbon canister (Figure 7).

Figure 7

1. Short hose
2. Hose adapter
3. Inline fuel-filter hose

Attach the 1.6 m (65 inch) hose to the fuel tank and fuel filter using the previously removed hose clamps as shown in Figure 8.

Note: Ensure that the hose is routed through the hole in the frame.

Figure 8

1. Fuel filter
2. Carbon canister
3. 1.5 m (61 inch) fuel hose
4. 1.6 m (65 inch) fuel hose

Attach the 1.5 m (61 inch) hose to the fuel tank and carbon canister using the previously removed hose clamps as shown in Figure 8.

Note: Shorten the hose if it is too long for your machine.

Attach the vent line hose to the carbon canister using the previously removed hose clamp (Figure 9).

Figure 9

1. Vent line hose

Snap the tie clip onto the side of the fuel-tank tray and secure the 2 fuel-tank hoses to it (Figure 10).

Figure 10

1. Tie clip

Install the previously removed battery and connect it to the machine; refer to your Operator’s Manual.

Install the battery cover.