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post #1 of 6 Old 08-29-2005, 07:51 PM
Posts: n/a
gas tank removal

What is the secrete for removeing tank. Owners book looks easy. There are two philips head screws that you can't get a screw driver on, not sure if they come out, book doesn't say so. Would like to put my K&N on.
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post #2 of 6 Old 08-29-2005, 09:55 PM
Join Date: Aug 2005
Location: Strongsville, Ohio
Posts: 81
When I read my owners manual and it told you how to remove the tank I thought "piece of cake". I took the seat off, then the plastic side panels, then the plastic piece that runs across the front of the tank. Now it says to unbolt the tank and lift it up using the prop rod. Well, the front fairing pieces are snapped onto the bosses for the bracket that holds the front plastic piece on so I gently snapped them off of the boss and then tried to raise the tank. It wasn't going well and I was afraid that I would scratch the tank so I ended up removing the side fairing pieces. To do this you have to remove the inner plastic pieces which are held on with some plastic pop rivets and some plastic screw rivets.(or whatever they're called) It sounds complicated but after you do it once it's not too bad.
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post #3 of 6 Old 08-29-2005, 10:17 PM
Join Date: Aug 2004
Location: SoCal
Posts: 211
Tank removal


Tank removal is something that will bcome old hat in short order - just about any basic maintenance or farkle additions are simplified once the tank is off. The owners manual is quite descriptive. Remove the seat, remove the "L" shaped, black plastic pieces (one 5mm allen bolt per side), remove the bolt on the back of the tank. Then you remove the plastic piece directly behind the steering/front fork assembly. The two little push pin "toggles" are removed by pushing the centerpiece inward with a small screwdriver to loosen them( about 1/4 inch) and then pull the entire toggle out. (To re-install these things, push the pin out to the top - protrudes about a quarter inch, insert toggle into body work, push pin back to flush position.) Remove the fairing bolts on the top of the tank and two each on both sides of the fairing. The fairing must be loose to expand as the tank is removed. On the front of the tank is a long bolt/nut combo - remove it. Depending on where you are, there are various hoses (slip off), the gasoline connection (need to release the catches to pull off) and an electrical connection (gas gauge) to disconnect. I hope you don't have too much gas in the tank at this point - the emptier the better! Carefully remove the tank lifting up and back - it will "open up" the fairings as it comes out - remember this for when you are putting it back. The two locations at the front-top of the tank where the tank (it has the threaded insert for the bolt) and the fairing connect need to be undone by lifting the fairing before moving the tank sometimes. No major force or effort is required so go slowly and carefully.

The airfilter box has numerous, deeply inserted phillips head screws to undo. Make sure the gasketing and the box top are properly seated when re-installing. On my bike, the front of the box is very close to the frame and it is a tight fit to get everything properly lined up, seated, and secured. If you don't get it right, you will here the induction noise. Must be done right to keep the crud out!

Remember to reconnect the hoses, the electrical connector,and the gas line (it clicks into position) and you are good to go. Getting the front bolt thru the tank mounts and frame holes might require an extra hand to hold the tank in the right spot, etc. All in all, its not too bad a process.

2004 dl650-the urban warrior.
2007 R1200RT - the highway beast
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post #4 of 6 Old 08-30-2005, 09:49 AM
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thanks, sounds complicated. there is a black metal arm that runs across the front od the tank. This has to come off or dicnnect somehow,
post #5 of 6 Old 08-30-2005, 10:15 AM
Join Date: May 2005
Location: Brackettville (150 mi from nowhere) Texas
Posts: 30
You should also check/tighten the throttle body boots while you're there.

'05 DL1000
'02 ACE 750
'03 TTR225
'79 IT175
'76 RD200
'75 TS75
'74 DT175
'73 G3SS90
'72 MC400 "Square Barrel"
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post #6 of 6 Old 08-30-2005, 11:07 PM
Join Date: Aug 2004
Location: SoCal
Posts: 211
Tank off

On each "side" of the bike, four of the hex head bolts have to be removed. Keep track of which bolt goes with which hole - thay have different shoulder heights. One of the bolts holds the "L" shaped piece (use your imagination - the one with the pebbly finish). It is also held on with two press fit connectors. One (this is on a per side basis) of the bolts is on the top front of the tank. You will have to lift the fairing "ear" up and off of the boss that is on the tank. The other two are on the side of the main fairing. This allows the fairing to expand as the tank is moved back, then up, then out. There is a small bolt/nut combo holding the front of the tank to the frame. If you only want to raise the back of the tank (sparkplug replacement) you only have to loosen these. To remove the tank - remove the bolt.

The manual is very good about this - take your time - be gentle - if it is right, no force is required (except if the tank is full). If it isn't working - look carefully for what is holding you up. Most likely it is the fairing ears on the tank top front bosses that are hung up. If I can do it, you can do it.

2004 dl650-the urban warrior.
2007 R1200RT - the highway beast
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