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Fuel Tank Removal
Phillips screwdriver ,
,slip joint pliers
,needle nose pliers
Warning: Gasoline is very combustible – avoid all sparks or flames. It is also a carcinogen.
Ride bike until you go onto reserve – getting
excess gasoline weight out of the tank makes this job much easier.
Unlock front seat with key and remove the front
Turn the fuel valve to OFF!!!
Insert a Phillips screwdriver down the center off
the fuel valve knob ~3 inches and unscrew the hidden screw until the
whole chrome knob assembly comes loose from the actual fuel valve. You
do not need to remove the chrome knob assembly, just pivot it down out
of the way.
Remove the front tank bolt using an 8mm socket and
Remove the rear tank bolt using a 12mm socket. Pry
up the rubber block under this bolt – it may be sticking to the frame
Lift the back of the tank a couple of inches being
careful not to catch the actual fuel valve on the “brake” line
With the back of the tank raised, pry off the small
fuel vent hose at the very back center of the tank. You may or may not
need to slide the clamp down the hose first with slip joint pliers.
You can now lift the tank a little higher and see
the two hoses that are attached to the actual fuel valve. Lower the tank
into place and go to the right side of the bike about 2 – 3 inches
behind and level with the ignition switch, you will find these two hoses
which are somewhat hidden. Pry off the small hose attached to the right
side of the fuel valve – it comes off easily without removing the
Still working from the right side of the bike,
rotate the clamp on the large fuel line so that you can get slip joint
pliers on it. Slide the clamp down the fuel line. Pry off the fuel line.
It will drip about a teaspoon of gas, so you may want to have a rag
under it as you pry it off.
Slowly lift the tank being careful not to catch the
fuel valve on the clutch line. Set the tank aside.
the above with the following notes:
Slide the two small clamps into place on the hose
before pushing the hoses on.
Wet the ends of the hoses slightly to make sliding
them on easier
I used needle nose pliers to slide the two fuel
valve hoses on from the right side behind the ignition switch. Don’t
forget the large fuel line clamp.
Be sure the chrome knob assembly is pointed to the
OFF position when connecting it to the fuel valve.
CHECK VAC LINE FOR KINKS
Be sure that there are no kinks in any of the fuel
and vacuum lines .
The author has done his best to produce accurate
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