Disassemble Fuel Tank

When installing a new fuel tank, it is necessary to disassemble the accessories from the old tank and to install them on the new tank.

The first step is to remove the old tank from the bike.

Place Bike on Centerstand.

Remove Seat.

Remove Left Side Cover. This shows the right but the left is the same.

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Remove Tank

  • Remove Front Tank Hold Down Bolt
  • Prop Up Front of Tank
  • Turn Petcock to OFF
  • Disconnect Tank Vent Hose
  • Disconnect Tank Drain Hose
  • Disconnect Fuel Hose
  • Disconnect Sending Unit
  • Lay Tank Back Down
  • Remove Tank Rear Hinge Bracket Long Bolt
  • Lift Away Tank

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Lay old tank next to new tank. At this point the old tank still has fuel in it and must be drained into an approved container. 5/16" Inside Diameter fuel hose works fine for the transfer. Attach fuel hose, point other end into a container and turn petcock valve to ON.

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When no more fuel flows shake the tank side to side and get as much to flow out as possible. You won't get it all. Then turn petcock to OFF and detach the fuel hose. Securely close the fuel container and store in a safe location. Next, turn the old and new tanks upside down.

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Transfer fuel petcock.

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Transfer Float and Sending Unit. When installed, turn the tank over and make sure the float is not stuck and moves up and drops back down freely. A long hooked probe to gently lift the float arm and a flashlight to see in the tank helps. Don't drop anything in the tank. If the float is stuck remove the float assembly and reinstall correctly.

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Transfer front hold-down bracket.

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Before turning the tank right side up again, go to a large sink or outside over some dirt or grass. As you turn the tank over more gasoline will drip out. Rock the tank around and get as much to come out as you can. Be careful, no open flames!

Next, transfer the rear hinge with the tanks right side up.

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Lastly, transfer the fuel filler cap assembly. Do NOT drop any screws into the tank.

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New tank ready for re-installation on bike.

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  • Lay tank down in place
  • Connect rear hinge
  • Reconnect sending unit
  • Prop Up Front of Tank
  • Reconnect Fuel Hose
  • Reconnect Tank Drain Hose
  • Reconnect Tank Vent Hose
  • Turn Petcock to ON
  • Lay Tank Back Down
  • Secure Front Tank Hold Down Bolt (10 Nm, 7.2 lb-ft)
  • Reinstall left side cover

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Carefully fill tank with fuel from container and make sure there are no leaks.

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Last Updated: 03-03-2005

Copyright © 2001-05, Patrick Glenn, All Rights Reserved.
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The information presented here reflects solely my personal experience with my motorcycle and is presented for entertainment purposes only. No information presented here is to be relied upon for issues of rider safety nor to replace the services of a qualified service technician. Any attempts to follow or duplicate any of these procedures are done so completely at your own risk. By reading the information on this site, you agree to assume complete responsibility for any and all actual or consequential damages that may arise from any information presented herein.