How to Remove the Gas Tank

kkim · May 24, 2008

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.

http://www.kawiforums.com/showthread.php?t=110849

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.

jhcrash · May 24, 2008

The CA. models will have 2 more hoses on the tank to remove. Other than that it is the same.

08jeremie250r · May 24, 2008

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

ninja250dad · May 24, 2008

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.......

kawisport · May 24, 2008

where's the pics,
need them to make this post better,
thanks,

Devilrey · May 24, 2008

I've found that propping the tank with rags/pair of gloves underneath the end of the tank keeps from scratching the bike.

deadheadred08 · May 25, 2008

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

kkim · May 25, 2008

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.

08jeremie250r · May 25, 2008

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

confused

and i just want to make sure i use the right ones

and harbor freight is a drive...

hoser · May 25, 2008

http://www.kawiforums.com/showthread.php?t=108573

kkim · May 25, 2008

hoser said:
http://www.kawiforums.com/showthread.php?t=108573

damn, boy... you following me around???

thanks for posting it up in the DIY thread. Think we could get a tech sub forum set up in the 250R forum?

NINJIXXER1000 · May 26, 2008

If you could put up some pictures of this, that would be greatly appreciated. I'm going to try shimming the needles this week and this is one of the major things that I'm concerned about doing correctly, but it does seem pretty straight forward.

Shade.Of.BlacK · May 27, 2008

Ok since people wanted pics, and Kkim has his hands full, I'll try an fill in the gap. Mind you the write up is still credited to Kkim all I'm doing is adding some visual aid. Don't want to start a new thread so I'll just add it in here.

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.

I used a piece of thick packing foam.

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.

Hope this helps....ok now back to the garage for the next 4-6 hours.

~cheers

NINJIXXER1000 · May 27, 2008

Thank you for posting up the pictures!

kkim · May 28, 2008

Shade.Of.BlacK... mahalo.

You've been a busy boy, too, I see.

Shade.Of.BlacK · May 28, 2008

kkim said:
Shade.Of.BlacK... mahalo.

You've been a busy boy, too, I see.

Had to maximize my time with the bike, woman coming home tomorrow then I won't have any time to work on it. At least not to the extent that I would like to.

All in all, not a bad use of two days. Got her pretty much where I want to, though I'm not entirely sure I'll stick with #102 on the MJs, but low-mid range I'm very much satisfied with.

deadheadred08 · May 30, 2008

i guess i get a petcock recall then, mine leaked out in the on position, thats what took me most of my time doing this, looking for something to let the tank drain into

NINJIXXER1000 · May 30, 2008

That's not good. I'm going to do mine this weekend and makes me wonder if I should have something near by just in case the same thing happens to me. Wonder why it leaked.

VeX · May 30, 2008

kkim said:
Do not leave it in the prime position as fuel will run out... ask me how I know.

...

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.

Ok I'll bite. How do you know?

I just put and Area P on and was waiting until Sunday-ish until I burnt the other half of gas out of my tank, but that tidbit about the vacuum actuated gas valve eliminates leakage. Time to play with the carbs

Thanks again for ANOTHER ++ write up kkim!

VeX · May 31, 2008

BTW for those who have asked, in California instead of having the vent tube WE have

The hoses are 'color coded' as you can see the red on the right (with a red dot on the gas tank), followed by a blue dot hose, and the regular vent hose all the way to the left.

And someone asked about hooking up a California gas tank to a non-Cali bike I would imagine you just have to plug those two lines... Here is the EVAP canister btw...

Enjoy!

Daves7m · Jun 5, 2008

Well just to add my 2 bits to the thred. If youd like to unhook the evap system then just unplug the Blue hose from the evap can. This line runs from the gas tank to the evap can and it plugs into the top of the evap can. Now plug the blue line into the red port on the gas tank. So you have a loop on the gas tank out the blue and back in the red. Now your red hose that is unplugged from the gas tank plug that into the empty port on the top of the evap can. BAM your done. When i have time i will pull the fairings and take pics of this and then i will show how to remove it all instead of just unplugging it. I did this on my wifes bike and did notice a nice difference in throttle response.

Dave

kawixxx · Aug 11, 2008

thanks. that was very helpful

Shifty250 · Aug 26, 2008

so in the cali model, if i remove the other 2 hoses on left front of the gas tank, gas wont come shooting out, will it?

VeX · Aug 26, 2008

Nope, they're for 'vapors'.

cypster · Oct 5, 2008

Hi Guys... I was about to go for my first real ride after the needle mod but I can't get my gas tank bolted down... the two bolts won't line up correctly with the holes...

Any ideas where I went wrong... I was so happy that I didn't lose any bolts but then this...

I hope one of you will be around soon... I wanna ride so bad today...

kkim · Oct 5, 2008

make sure the tank is slid all the way forward onto the two rubber doughnuts toward the front of the tank. I lubricate rubber parts with armorall so they don't hang up. also, make sure your tank bracket (the one w/ the 2 10mm bolts) is faced the correct way. there is a small arrow showing you which way should point towards the front.

cypster · Oct 5, 2008

Thanks kkim. I'll give it another shot.

cypster · Oct 5, 2008

I just rode 15 miles and it felt like I was flying (at the speed limit of course). hehehe. :woot::thumbup: thanks again kkim. The problem was with the fairing... I know now that I can't tighten any of the four gas tank fairing screws until I get them all inserted or else I won't be able to get the gas tank in place... Man I can't wait until I stop being a newb so I can actually give something back instead of always looking for help. lol. Well I'm about to go out again.

kkim · Oct 5, 2008

lol... enjoy, man.

thebeansoldier · Oct 6, 2008

Thanks for the write-up and pics. Removing the tank was a snap. Is there any gain just capping the evap barbs on the tank?

VeX · Oct 6, 2008

Well, I figured kkim would jump on this? I guess not! You will gain nothing by capping (and removing) the evap equipment...

... You'll lose about 4-5 lbs of pointless emissions equipment though

You have a Cali bike I'm guessing? Take notice that you don't plug BOTH ports if you do pull them btw. You have to leave the blue-dot port open!

How to Remove the Gas Tank

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