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Old 05-24-2008, 03:07 AM   #1 (permalink)
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Default How to Remove the Gas Tank

Taken from another post I made a few months ago. I thought it might come in handy for anyone looking to remove the tank...

Take off both the side covers and lower fairings.

Let's Get Nekkid!!!

This is for a 49 state bike. If you have a cali model there may be more steps/hoses than this to remove the tank.

1. Take seat off. One Allen on each side of the seat. There is a washer inside each mounting hole of the seat. Don't lose them.

2. remove 2 10mm bolts at the rear of the tank along with the bracket they hold down.

3. prop up the rear of the tank with a small piece of 2x4 so you can gain access under the tank.

4. unplug the gray vent hose from front left side of the tank.

5. under the tank, undo the fuel sender connector.

6. under the tank, remove a vacuum hose that runs to the fuel petcock.

7. under the tank, make sure the fuel tap is in the "on" position and remove the hose from the fuel petcock. The valve is vacuum operated and with no vacuum, no fuel will pour out of the tank as long as it is in the "on" position. Do not leave it in the prime position as fuel will run out... ask me how I know.

At this point you should be able to lift the tank off by pulling the rear of the tank up and towards the rear of the bike. Make sure the black console plastic that wraps around the upper tank fairing mounting holes are free.

When you put the tank down, make sure you place it on a blanket or cloth to avoid scratching it and don't let it rest on the petcock. I use a small 2x4 under that area ahead of the petcock to make sure the tank isn't resting on it.

No need to drain the tank before removal, but if you do start with a full tank, it is quite heavy compared to it empty. Again, ask me how I know.

Last edited by kkim; 05-24-2008 at 03:59 AM.
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Old 05-24-2008, 04:07 AM   #2 (permalink)
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The CA. models will have 2 more hoses on the tank to remove. Other than that it is the same.
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Old 05-24-2008, 09:56 AM   #3 (permalink)
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HA HA
i was thinking about this last night around 11 or 12
I'm going to be doing my mods this weekend and this was the hold up
kick ass!!!
Thanks rep for you
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Old 05-24-2008, 11:35 AM   #4 (permalink)
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Quote:
Originally Posted by kkim View Post
Taken from another post I made a few months ago. I thought it might come in handy for anyone looking to remove the tank...

Take off both the side covers and lower fairings.

Let's Get Nekkid!!!

This is for a 49 state bike. If you have a cali model there may be more steps/hoses than this to remove the tank.

1. Take seat off. One Allen on each side of the seat. There is a washer inside each mounting hole of the seat. Don't lose them.

2. remove 2 10mm bolts at the rear of the tank along with the bracket they hold down.

3. prop up the rear of the tank with a small piece of 2x4 so you can gain access under the tank.

4. unplug the gray vent hose from front left side of the tank.

5. under the tank, undo the fuel sender connector.

6. under the tank, remove a vacuum hose that runs to the fuel petcock.

7. under the tank, make sure the fuel tap is in the "on" position and remove the hose from the fuel petcock. The valve is vacuum operated and with no vacuum, no fuel will pour out of the tank as long as it is in the "on" position. Do not leave it in the prime position as fuel will run out... ask me how I know.

At this point you should be able to lift the tank off by pulling the rear of the tank up and towards the rear of the bike. Make sure the black console plastic that wraps around the upper tank fairing mounting holes are free.

When you put the tank down, make sure you place it on a blanket or cloth to avoid scratching it and don't let it rest on the petcock. I use a small 2x4 under that area ahead of the petcock to make sure the tank isn't resting on it.

No need to drain the tank before removal, but if you do start with a full tank, it is quite heavy compared to it empty. Again, ask me how I know.
Good writeup! I did mine this last week working on mine. I just slopped a little gas on the floor from the carb when I took the big line off. Left the fuel in the on position until I got a gas can handy, then turned to prime. Takes a while to drain 4 gallons of gas through that line. Ask me how I know.......
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Old 05-24-2008, 03:18 PM   #5 (permalink)
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where's the pics,
need them to make this post better,
thanks,
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Old 05-24-2008, 04:38 PM   #6 (permalink)
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I've found that propping the tank with rags/pair of gloves underneath the end of the tank keeps from scratching the bike.
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Old 05-24-2008, 08:25 PM   #7 (permalink)
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thats funny cause i did my "raising the needle mod" and snorkel removal about 3 hours ago, and the thing that took the longest was finding something to let the fuel tank drain into, cuz i unplugged the vacuum line and then the fuel line, and it was constantly dripping from the petcock so i replugged it and went searching, but you said that it wouln't drain while it was in the "on" position, and that was not so for me,but i got the job done and the bike is night and day, i noticed it immediately when letting out the clutch
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Old 05-24-2008, 08:44 PM   #8 (permalink)
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Originally Posted by deadheadred08 View Post
thats funny cause i did my "raising the needle mod" and snorkel removal about 3 hours ago, and the thing that took the longest was finding something to let the fuel tank drain into, cuz i unplugged the vacuum line and then the fuel line, and it was constantly dripping from the petcock so i replugged it and went searching, but you said that it wouln't drain while it was in the "on" position, and that was not so for me,but i got the job done and the bike is night and day, i noticed it immediately when letting out the clutch
Did you take the fuel line off at the petcock or at the carb?

If at the petcock, that is odd as I've had the tank off numerous times and it has never dripped.

Glad to see you're happy with the shimming. The bike is delivered way too lean from the factory.
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Old 05-24-2008, 08:54 PM   #9 (permalink)
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hey kkim how about i papal you 5 bucks for you to send me some washers
i know, i know, I'm lazy
but i don't have a micrometer or digital caliper ()
and i just want to make sure i use the right ones
and harbor freight is a drive...
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Old 05-24-2008, 09:07 PM   #10 (permalink)
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2008+ Ninja 250 Mod/DIY/FAQ
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