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[T MAC]

How hard is it to remove the gas tank?  I read the manual and it seemed a little complicated but sometimes the manual makes it seem harder than it is.  I am installing a TTS mastertune and need to remove the Techlusion that the dealer installed.  I have lifted the tank but cannot reach under tank to disconnect the injector plugs and the only way is to remove the tank.

I can go to the dealer if I have to but it can't happen until Thursday so if I can tackle this before then I will.  I also have new mufflers and 12" Bitubos I am installing.

Thanks....

[FR8TRN]

If it's an '07 or earlier you have to remove the console and attached wiring, the crossover on the bottom front of the tank, the fuel line on the clutch side, bolts in the front and the one on the rear tab under the front part of the seat, not too hard.  If it's an '08/later, then all that but the crossover on the bottom front.

[hd-dude]

You can most likely remove the bolt at the rear of the tank and lift it from the rear to gain enough access. If not then you can remove the two front mount bolts as well and lift it up high enough to gain the needd access without disconnecting the fuel lines.

[Sklywag]

If you are going to remove the tank, there is a process.  The fuel line connects to the tank with a quick disconnect fitting.  Do not cut the hose, the fuel line is a high pressure line.  You remove the entire fitting similar to removing a connection from an air hose.

1st, remove the seat.

2nd, you have to relieve the pressure on the line from the fuel pump.  To do this remove the fuse that powers the fuel pump.  This is under the right side cover, not with the main fuses.  Once you have removed the fuse, stat the MC, let it run out of fuel & die.  Now the line has no pressure in it.  

3rd, Remove the console, take out two bolts under the gas door & one at the rear, put a towel over the battery area, fold the console back & lay the console on the towel.  Remove any tie wraps that hold the wiring in place so you will be able to slide the harnesses over the tank as you remove it.  Easier with 2 people.

4th, You can now push up on the chrome fitting on the fuel line & slide the collar down & the line will disconnect.   Wrap it in a rag, it may drip gas.

5th, Now that the fuel line is disconnected you need to remove the cross over hose.  You should do all this with minimal gas in the tank.  This next step takes 3 hands.  carefully with a pair of dikes, cut off the metal clamp on the left side of the hose, don't cut the hose.  Next you need a 1/4" or 5/16" rubber plug ( I don't remember the fuel line size), that will go over the fitting from the tank when you pull the hose off.  Also have a 1/4" or 5/16" bolt, piece of solid plastic, or something to put into the hose end when you remove it.  You don't need to remove the hose from the right side.  Just let it hang.

Ok, to get the hose off you will pull it off the tank fitting & immediately put a finger over the hose end & the tank fitting.  Yes, some gas will leak.  Now have someone put the plug over the fitting or the plug in the line, then plug the other one.

If you don't prepare for this you will have gas everywhere.

Once you have the fuel line off & the crossover off, remove the bolts & the tank just lifts off.

Reverse this process to put it all back on.  

It isn't as difficult as it might seem if you are mechanically inclined.  If you don't work on the MC & have the dealer do everything I don't recommend that you do this.

Good luck should you accept this mission........

[T MAC]

I think I will try to lift the tank up and see if I can reach the injectors as Jim suggested, if that does not work then I will probally just take it to the dealer.  I always keep my tank full of gas in the winter....so the tank is full right now.  I Appreciate the detailed info.




THANKS!  For the Help & Info

[hogasm]

Do as  Sklywag posted for removing the tank except removing the crossover line.

If you want to drain the tank....get another fuel hose from someone that changed over to a stainless one. Remove the end that connects to the TB. Plug in the tank end and put the other end into a fuel container.
Reinstall the fuel fuse
Turn on the key and put the kill switch on run
Fuel pump will run and drain the tank
Now you can remove the crossover line and remove the tank

[HDDOCFL]

Do as  Sklywag posted for removing the tank except removing the crossover line.

If you want to drain the tank....get another fuel hose from someone that changed over to a stainless one. Remove the end that connects to the TB. Plug in the tank end and put the other end into a fuel container.
Reinstall the fuel fuse
Turn on the key and put the kill switch on run
Fuel pump will run and drain the tank
Now you can remove the crossover line and remove the tank

This method works well but you will still lose gas when you pull the crossover line off unless you prepare for it as mentioned in above post. If you plug both ends of the cross over you can remove the tank on a FI bike with out draining the tank.    Doc

[hogasm]

This method works well but you will still lose gas when you pull the crossover line off unless you prepare for it as mentioned in above post. If you plug both ends of the cross over you can remove the tank on a FI bike with out draining the tank.    Doc

True...but it sure beats the hell out of having to catch 5 gallons of fuel instead of a few ounces and a few ounces is alot lighter than 5 gallons

[DICKW]

It isn't as difficult as it might seem if you are mechanically inclined.  If you don't work on the MC & have the dealer do everything I don't recommend that you do this.

Good luck should you accept this mission........

I say go for it, not at all difficult.

[T MAC]

  I got the Techlsuion removed tonight - lifted the tank as Jim recommended and took right side bolt out was enough to reach my hand in and disconnect/reconnect injectors.  I took the A/C off also.  Man - It always feels Good to work on the scoot!  I was a little nervous that lifting the tank up would disconnect or cause stress to the lines to the tank but I just needed it a little higher. 

THANKS FOR THE INFO AND VOTE OF CONFIDENCE -  I was about to just take it to the dealer but I thought that I needed to check you guys to see if I was missing something, as always I got the info I needed.

I am going to install the TTS mastertune tonight and get my original map, also install my new screamin eagle mufflers and 12" Bitubos (that arrived today)

I have some items I am going to put in the sell thread hopefully in the next few days - I have said this for months now but never get to it- rinehart slipons, new mustang seat, grab rail, heat shields and intercom headsets.

[Sklywag]

Awesome!  Glad it worked out for you.

What Mustang seat do you have for sale?

[T MAC]

I have the 79127 model with large passenger pillion, seat nuts and fender bib.  It is a Nice seat - I bought the seat then 2 days later Matt on the site had a Corbin solo with passenger pillion (flame stitched) for sale and you know us - after thinking about for a week I decided to buy it also.  I wanted a solo/pillion option since I made my tour pak detachable.

I rode with the Mustang seat for about 100 miles can't say that I did or didn't like because I rode such a short time on it - it was comfortable and as far as reach it was the same as the Corbin for me. 

When I returned from my intial ride with the Mustang seat the UPS man had left a box on my porch.   I put the Corbin seat on the bike and I guess since my last seat was a Corbin this seat just fit me, so I put the Mustang on the shelf and figured I would keep it or offer it on the site for someone.  I just never seem to find the time to take pictures so I have not put it on the site yet. 

Since I have changed the exhaust and now have the rineharts for sale also I will try to get some pictures taken and posted

but tomorrow we are supposed to have some sun so...



  I WILL BE RIDIN'