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Discussion Starter #1 (Edited)
2018 update- I'm Back! This thread is being restored with the original photos, (some not so good - I know) They are now resident on this site in my Gallery Album. Enjoy, DSR650

How to lift the tank and open the airbox on the new VStrom 650. The model here is a 2012 DL650A-L2 ABS Adventure with a custom Matte Metalic Vinyl Wrap on the bodywork. Bike is on a centerstand (from HappyTrail), makes service much easier.

This job is straightforward and can be done with the factory tool kit. It takes about 20 minutes the first time through.

Preparation:
1. Put the bike in a safe work area.
2. Remove the seat
3. Get the factory toolkit out.

Tools needed -
1 small Hex Key Wrench
1 medium Hex Key Wrench
Cross Tip Screwdriver
Pliers
12mm Wrench
Rag to catch fuel from hose.

The Tank Removal Job can be broken down into 7 steps:
1. Remove Tank Side Covers.
2. Remove Tank Mounts
3. Lift Tank.
4. Remove Fuel hoses
5. Remove Tank
6. Open Air box.
7. Remove Air Filter.

Tank Cover removal:
Pull the 4 screw from each side cover. I put all the screws in the tool kit tray under the seat.

Here are some photos:
SideCover Rear Screw Removal


Frame Cover front Screw Removal:


Lower SideCover Screw Removal:


Front Side Cover Screw Removal:


Side Cover Removal takes two hands and a bit of fiddling to release the industrial hook and loop and disconnect from the ABS top cover. One hand goes high and the other low. Like this:

Sidecover Pull Away from Tank - Upper Rear


Sidecover Lift Up and Pull Back Toward Seat


The Frame Cover has a barb that grabs the Side Cover and there is a large post that fits into a bushing on the frame. You can pull it loose if it does not pop off itself.




Repeat on the other side of the bike and the tank covers will be off.

DSR650
 

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Discussion Starter #2 (Edited)
Okay, now there is a trickly little screw for the Radiator Shroud that was covered by the Tank Side Cover. Pull this screw from each side:



Now, let's get the Top of the Tank Un-covered.

Remove the screw on the rear edge of the fairing extension on top off the tank:



Pop the push-lock connector in on the front of the tank cover sides:


Here is what it looks like when it is ready to remove:


Press it out from behind with your fingers and catch in your palm:


Now separate the top cover from the fairing extensions and lift off the tank posts:



The top cover has a post in the middle that pushes into the front tank mounting bracket. Lift the cover to pop it loose and then work the tabs out from the fairing extensions:



This exposes the front tank mount:


Okay... that's the end of the plastic.. time to unbolt the tank from the frame.

DSR650
 

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Discussion Starter #3 (Edited)
The Tank Lift is near:

Remove the two front tank mount Screws on the bracket the top cover attached to.



Remove the rear tank mount bolt, lift the tank bracket off, and be ready to catch the rubber tank mount pad:


Now lift the rear of the tank and place the tank support bracket into the two holes on the tank mount. The tab on the other side goes into the large mounting hole:


Fuel System Disconnect:
Disconnect the fuel pump electrical connection - the White connector in the above photo. It has one locking tab that needs to be pushed in, then pull the connector apart.

Next, put a rag under the fuel line, on top of the engine to catch any fuel that may spill.

Now take a look at the fuel line connector: This is how mine was sitting, it looks a little out of alignment but was secure and not leaking at all. There are two blue tabs that lock into the body of the black fuel connection. One on each side.



To disconnect, squeeze the blue tabs in and pull the black connector off. Like this:


Now for the two other hoses attached to the tank on the left side. The forward one I'm pretty sure is the fuel return line. It does not have the nylon braided cover and it can be hard to get to. One way is to follow it to locate the other end and remove it from there, as I've done in this photo:

Tthis photo is from the right side of the bike :


Last, disconnect the vent line, up on the tank, I use the pliers to pull the clamp down first then slide the hose off:


The tank is now free and can be lifted off the bike, here is the airbox exposed:


DSR650
 

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Discussion Starter #4 (Edited)
Air Filter Inspection

Open the Air Box using the Screw driver:



Lift the airbox lid:



Here is the filter as it sits in the bike, there is an UP on the filter flange if you get confused. This filter has 10.5K miles on it - almost all street with lots of highway running:


Here is the bottom of the air filter, complete with a curiously strong and heavy metal screen:


And here is the lower airbox with the tuned intake ports:



There ya go... not so bad really. 20 minutes and it's back together too.

DSR650
 

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Great job!

Wow, you did a great job demonstrating how to remove the tank and inspect the air filter. I was planning to check my filter and do some wiring soon but I was a little hesitant because I wasn't sure how difficult it would be to do this. Now I'm looking forward to it. Thanks so much for taking the time to do this.
 

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Very helpful post. Thank you! Bookmarking this thread now. :cheers2:
 

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FORUM GODFATHER.....R.I.P. PAT
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Good info. Stuck in the 2012+ DL650 forum since it is model specific.
 

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Thanks DSRider650, much appreciated, although I'm going to try and get away without removing the tank to clean the filter.
 

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FORUM GODFATHER.....R.I.P. PAT
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The tank has to be removed to get at the filter.
 

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This is a great post, thanks for making it a sticky. I've been dreading the tank lift, but not so much when I have a visual reference to follow.

To date I've been able to wire in the Eastern Beaver headlight relay and a PC-8, that is running many things, without removing the tank. I've done it mostly by routing through the left side, under the tank and over the radiator, following a factory bundle. It takes a bit of patience and effort to fish some of the wires, but wasn't too hard.

Now the air filter..I guess I can't avoid that.

Thanks for the how to on how to!
 

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I tackled this job today and found your pictures and description to be most helpful. The only thing that was tough for me was the fuel line disconnect. I couldn't do it bare handed but used a small vice grip to pinch the blue tabs.

I labeled all the fasteners and taped them to to a legal pad. Jeez, 26 fasteners to remove to clean the air filter. I added the wiring for a cigarette plug/switch/USB unit while I had the tank off.
 

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Discussion Starter #15 (Edited)
Good job, and I agree this is a bit excessive to get to an air cleaner. this is not hard, and I think the plastic will hold up fine over time.

DSR650
 

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How low does the fuel need to be to avoid major spillage?
I did the lift on a full tank with no spillage. But the tank was d&ng heavy and awkward to get off. I recommend waiting until you are on the emptier side.
 

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Discussion Starter #20
The cloth to catch any fuel spill is from the service manual. The pump itself did not appear to leak, but I did have a little fuel from the hose end drip out. I happened to have the tank at about half full, certainly less gas is preferred but this can be done with a full tank too.
 
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