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Discussion Starter #1
guys I'm going to remove my tank and start some mods, but i have a few questions.

1. is there something I need to do to keep te fuel from leaking out? and i guess that would be answered by my second question...

2. Does anybody have any step by step instructions on how to do this? (illustrations or pics would also be a plus)


Thanks guys.
 

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Do you have the service manual?
 

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No need to empty the tank, but it's easier to handle with less gas in it, simply due to the weight.

1. Remove side covers
2. remove seat bolts and seat.
4. place a clean microfiber between the front of the tank and the triple tree to keep it from scratching for step 7.
4. Loosen, but do not completely remove the two tank strap bolts at the front of the tank
5. Remove the rear tank bolt and washer
6. Pull the vent and drain lines out of their drain hoses on the left side of the bike at the front of the side cover.
7. raise the tank at the rear and place a small block of wood under it to keep it raised a few inches
8. loosen the worm clamp that secures the fuel line to the bottom of the tank. You can use a flat screwdriver or I believe an 8mm socket. Shouldn't need the rachet, just an extension turned by hand. There will be a small amount of fuel that leaks out. I usually place a rag or paper towel under it before I loosen the clamp
9. Gently pry the fuel line off of the tank nipple. Rotating back and forth helps with this.
10. disconnect power to fuel pump at the connector under the tank.
11. remove block of wood or other wedge device, and remove the two front strap bolts
12. carefully lift tank straps over frame.
13. tank should come up and off...

Once you get the hang of this, the whole process takes less than 5 mins.
 

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Discussion Starter #8
thanks guys, that was extremely easy, the hardest part was getting the fuel line away from the fitting, those damn things are on there good!

I'm very happy now! I wanted to fabricate a "cold air intake" like Lloydz torque tubes.... it's going to be extremely easy to do this with the factory internal air box, just a little time with the dremel and some bungs/grommets for the air flow sensors and i should have a cleaned up front end and "cold air intake". i'll post pics and everything as soon as I'm done.
 

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derek,
before you button her back up you might
want to clean those throttle bodies.thumb up
 

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derek,
you will have to cut it out,unless you want to
pull the motor. on those throttle bodies just use
a good quality name brand carb cleaner.;)
 

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Discussion Starter #17
everything is going to work, i'm just going to get a metal plate cut to install on the front for the air temp sensor to be mounted in and seal the front end up. hoping to get it done thursday or friday and get the bike back together. it's going to look sweet.
 

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Discussion Starter #20
i got side tracked.... had a few things come up and haven't had the time to work on it. I'm hoping to get back at it with-in the next few weeks. i have to get everything finished up soon, riding season is almost here!
 
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