Fuel Tank Removal

[GSmonkey]

Anybody had a go at removing the fuel tank?? Seems like something I may want to do in the near future so thought I'd look into how to do it.

I've noticed that there are four bolts holding it down. I guess that I can undo the four, rotate it back on the rear lugs, then unhook any tubing?? Can't see any obvious place to unhook the piping from the outside of the tank, are there push fit connectors below the tank?

Come to think about it, are there any downloadable workshop manuals for the 1200 available yet??

 

[Marty Hill]

motobins.com will sell the cd. Tank comes off very quickly.

 

[Mouse]

Sounds like what you think is the tank is actually the tank cover?

From memory, this is the procedure:

Remove black (or grey) plastic side panels. Unscrew the 4 small torx screws that hold the tank cover on - there's 2 at the front, one behind the small black plastic cover on the left hand side and one on the right side. You then need to also remove the filler cap by undoing the 6 torx screws holding that down.

The tank cover (comprising one coloured bit of plastic and two aluminium side panels) shoudl then lift away.

Undo the fuel lines from both sides of the tank - they have quick release connectors. Also undo the vent lines, these just push on.

Then undo the two large Allen bolts, one either side of the tank. The tank should then lift away - it's also mounted on two lugs at the front, so lift from the back and pull backwards at the same time.

I hope that's right, all from memory.

 

[Emoto]

Do the quick release connectors need to be plugged when you disconnect them to prevent fuel running out everywhere, or do they have cut-offs in them?

 

[Mouse]

They cut off when disconnected.

 

[Dutchman]

Sounds like what you think is the tank is actually the tank cover?

From memory, this is the procedure:

Remove black (or grey) plastic side panels. Unscrew the 4 small torx screws that hold the tank cover on - there's 2 at the front, one behind the small black plastic cover on the left hand side and one on the right side. You then need to also remove the filler cap by undoing the 6 torx screws holding that down.

The tank cover (comprising one coloured bit of plastic and two aluminium side panels) shoudl then lift away.

Undo the fuel lines from both sides of the tank - they have quick release connectors. Also undo the vent lines, these just push on.

Then undo the two large Allen bolts, one either side of the tank. The tank should then lift away - it's also mounted on two lugs at the front, so lift from the back and pull backwards at the same time.

I hope that's right, all from memory.

Not bad, from memory, Mouse.......

However it's not necessary to remove the painted top panel, alloy side panels or fuel filler in order to remove tank.......these won't get in the way of removal either....

The biggest single aid to removing the tank is to ensure it's nearly empty of fuel.......it'll be much lighter & easier to re-fit.....

Cheers

Dutch

 

[Mouse]

Dutch - are you suggesting removing the tank with the painted panel and ally side panels still attached to it? I didn't think of that - it would save having to remove the filler cap, which is good. I assume then you can get to the fuel line connectors with the panels still in place ... can't quite remember the layout.

 

[Dutchman]

Yes, that's exactly what I'm suggesting, leave the painted & alloy bits in place, they are fitted directly to the black plastic fuel tank via the six fuel filler retaining screws........

The right hand fuel connector & breather tubes are attached forward/side of the tank, exposed when the larger plastic side panel is removed and the left side fuel connector (and two electrical connections) is on the upper left side of the tank, again exposed when the left plastic panel is removed. These connectors are under the round black plastic clip-on cover.

Cheers

Dutch

 

[GSmonkey]

I assume that the plastic cover does not get in the way when you rotate the tank on the rear lugs to remove??

How do the quick release connectors work (if its not too stupid a question)??

 

[Dutchman]

I assume that the plastic cover does not get in the way when you rotate the tank on the rear lugs to remove??

How do the quick release connectors work (if its not too stupid a question)??

There are no rear lugs......just the two at the front.

Slacken the forward allen bolts & remove the rear ones......then lift the rear of the tank, just an inch or so, (I placed rag between the painted tanktop & the frame to prevent damage) then lift up & away......

The quick release connectors have a wee button on the side....just depress and remove the connector....this cuts of the flow of petrol at the same time.

Finally, before I adjourn to the pub......I have to ask........why is everyone wanting to remove the tank.......there's not many user friendly bits under there.......my excuse was (a) noseyness and (b) fitting of passive security devices.......

Must go, the Guinness is calling me........

Cheers

Dutch

 

[Mouse]

There are no rear lugs. There are two lugs at the front, at the rear there are two Allen bolts which you have removed by this stage

The quick release connectors should be obvious when you look at one - you push a metal tab and it pops apart.

Edit - Dutch beat me to it!

Another edit - I removed the tank to route some wiring for my front power socket along the main loom. Probably not totally neccessary but gave me more room to work. Plus, noseyness

 

[GSmonkey]

Sorry, when I said rear I was thinking the back of the tank as you sit on the bike, which I suppose is the front. Sh!t I should go for a bear

I'm just being nosey and may well route some cables round there for future mods e.g. auxiliary lights etc. Also like to give things a good clean once a year and the more you can get rid of things in the way, the easier the job.