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[deaf1]

Finally tried to get the tank lifted up...  There doesnt seem to be and good way to get wired and a larger loom (for the motolights) in there w/o taking the tank off.

Other then the 4 bolts, what else will I have to disconnect?  There is the loom that goes to the cluster,  and a few things I can kinda see under the tank.  I dont know why I didnt have the dealer do this when it was in for service for the alarm,  but I had a brain fart.... 

Thx
Scott

[103_RK]

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts).  there is a channel there to run wires through.  You don't need to remove the tank.  At least it's that way on my 03 SERK.

[Sean M Cary]

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts).  there is a channel there to run wires through.  You don't need to remove the tank.  At least it's that way on my 03 SERK.

103 - I need to take mine off this week to run wire for my Zumo, is there a gasket in there that I need to replace if I take this off?

Not at home, or I would just look in my manual.

Sean

[deaf1]

Just remove the chrome dash that covers the center of the gas tank (the part where the spedometer mounts).  there is a channel there to run wires through.  You don't need to remove the tank.  At least it's that way on my 03 SERK.

That would ROCK!  I havent been in the garage (freezing)  But what do I need to get the instr. cluster off?

Scott

[Twolanerider]

103 - I need to take mine off this week to run wire for my Zumo, is there a gasket in there that I need to replace if I take this off?

Not at home, or I would just look in my manual.

Sean

There is a rubber gasket that is the interface between the dash and the tank Sean.  Actually seals nothing though.  Just there to avoid the metal on metal contact.  You don't replace it.

[Twolanerider]

That would ROCK!  I havent been in the garage (freezing)  But what do I need to get the instr. cluster off?

Scott

Two fasteners.  Both out in the open and obvious.  One center high between the speedo and ignition switch and one center low just above the seat.  The lower one might have the head of the fastener hidden by a decorative bezel that is commonly used.  Taking the dash off is half the battle of tanking the tank off.

[Talon]

I would do like 2LR is saying, just remove the rear mounting screw and loosen the front two. It's not major work to take the tank off, but a pain! Have to drain it, remove hoses, take the dash out to get to the wiring. I'd try it first and see. I just ran new throttle and clutch cables. I did the reverse for the throttle cables. left the back screw loose, and pulled the front two, it gave me enough room to get in and route the cables even with the crossover hose still connected. Some times you just need to get in there and see what works for you. Good luck.

Craig

[J-Carr]

Can I just add that lifting the tank too far without disconnecting the fuel line can break the plastic nipple at the injector side... At least on a Dyna.  Can I also add that trying to finagle it back together afterwards unitl an overpriced replacement peice comes in from HD can cause the bike to break down on the side of the road and piss you'r wife off really bad.  Don't ask how I know this... I'm not tellin!

My recolection is that draining the tank prior to removal isn't necessary other then for weight reduction on a fuel injected bike.  When you pull the injector fuse and run the bike til it stalls it will have eliminated the preasure and the valve in the tank where the petcock used to be won't open. So the gas stays in.  Right?

Ride Safe,
J-Carr

[Twolanerider]

So the gas stays in.  Right?

Ride Safe,
J-Carr

On a newer tank without the external fuel crossover line that's correct JC.  With the crossover you'll either have to drain fuel or have put a quick disconnect in the line first.  If the tank is coming off I've often not drained it on the bike though.  Couple of small vice grips or large forceps; one close to the tank nipple on each side.  Cut the hose in the middle.  Stick a bolt in each side.  Take off the vice grips or forceps.  Lift away.  With the tank away from the bike you can then more easily drain the lines in to a gas can and then install your new line with a disconnect in it .

[J-Carr]

On a newer tank without the external fuel crossover line that's correct JC.  With the crossover you'll either have to drain fuel or have put a quick disconnect in the line first.  If the tank is coming off I've often not drained it on the bike though.  Couple of small vice grips or large forceps; one close to the tank nipple on each side.  Cut the hose in the middle.  Stick a bolt in each side.  Take off the vice grips or forceps.  Lift away.  With the tank away from the bike you can then more easily drain the lines in to a gas can and then install your new line with a disconnect in it .

Thanks Don,

That was my recollection as my son and I lifted the tank off together from each side so the weight wasn't an issue.  I thought it was much easier then fishing wire and I know it's all tied down nice and neat under there.

Ride Safe,
J-Carr

[Twolanerider]

Thanks Don,

That was my recollection as my son and I lifted the tank off together from each side so the weight wasn't an issue.  I thought it was much easier then fishing wire and I know it's all tied down nice and neat under there.

Ride Safe,
J-Carr

That's what I prefer also JC.  Just like making sure cabling or wiring won't later develop a rub and is tied in place where I want it.  I also never cared for draping wiring over the tank under the dash.  Since the tank does need to come off occasionally it's just that much more in the way when it does.  Just easier to do it once, do it right and have done it that way the first time.  Then never have to think about it again.

I've had mine on and off several times even when full of fuel.  With the quick disconnects in the crossover just never worry about fuel loads.  They aren't so heavy nor so wide that they're actually difficult to handle.

[Talon]

Yea, but like you said, if you don't have the disconnect on the crossover, you do have to drain the tank, not a big deal, but I was able to get the tank high enough so I could see the lower half of the top frame tube and cable looms, it was easy, I would assume you could do the same on the other side, didn't really look.

[J-Carr]

Yea, but like you said, if you don't have the disconnect on the crossover, you do have to drain the tank, not a big deal, but I was able to get the tank high enough so I could see the lower half of the top frame tube and cable looms, it was easy, I would assume you could do the same on the other side, didn't really look.

Actually, I never did drain it on my old bike or on now on my wife's Dyna.  I run the fuel out by pulling the fuse and running until it stalls so the preasure's off the tank.  Then clamp off the hose with Vise Grips on one side.  Pull the line from the other side and quickly slide a spare hose that's plugged onto the open nipple.  Spill no more fuel then we do draining it.  Don't even need to clamp it to get it stay.  When we're finished we just lide it back on.  We replaced the crimp clamps with screw clamps to make it easier.

Ride Safe,
J-Carr