Fuel Tank Removal

ALWAYS EXERCISE INTENSE CAUTION WHEN HANDLING GASOLINE!

Fuel tank removal is required for many other procedures on this bike, such as gaining better access to the carburetors or to change-out a weak condenser (as I had to).   It's pretty easy, actually.   You just need to be extremely careful with the fuel.  No smoking, need good ventilation, and all the good things you've heard a million times before.    Remember, what you do to your bike is your own business, I'm only describing the process that worked for me.   I am not responsible if you mess up your bike or cause a giant explosion in your garage. 

 

1)  Turn the Fuel Petcock to the "STOP" setting.  We don't want any fuel dripping yet.

 

2)  Remove the fuel hose from the right carburetor.

3)  Somehow build an extension on the fuel hose, so it will be long enough to reach your gas can on the floor.   I grabbed a brake hose I had lying around, and taped it really well to the fuel supply hose.

 

 

4)  Insert the drainage hose to the gas can ON THE FLOOR.   Open the Fuel Petcock to the "RES" setting.   This way you will drain the reserve tank as well as the main tank.    Watch for leaks in your make-shift drain hose.   If nothing drains, then you may have an issue with the ventilation holes in the fuel tank lid (or your tank is already empty!  hahaha!).   Opening the tank lid may speed the draining process.  DO NOT leave the bike unattended while draining.

 

 

5)  With all the fuel drained from the tank, you must disconnect one side of the connector hose joining the left and right halves of the fuel tank. 

 

6)  Go ahead and detach the left carburetor's fuel line at this time as well.   It is located on the Fuel Petcock, right next to the right side fuel supply line.   Disconnect your make-shift drain hose extension from the right side's fuel hose.

 

7)  Now we are almost ready to lift the tank off the frame.   The tank is not attached with any screws or bolts or clamps.  Just a rubber bracket.   Raise the seat, and pry the bracket at the rear of the tank, so you can get the tank loose.

Out of the rubber bracket....

 

8)  The front of the tank sits on two pegs for support, but is not attached to them.  Lift the tank off the frame, pulling slightly towards the rear of the bike.   Be careful not to spill gas when you lift the tank, since it is not 100% empty.   Leaning it forward (raising the rear of the tank) helps a lot, since the front of the tank has no holes.

 

9)  Installation is the reverse of removal.   Put tank on frame, reconnect all 3 hoses, close Fuel Petcock back to "STOP" position, and fill 'er up.

 

DISCLAIMER:  The process described here may not be the very best method known to man. It is a description of worked for me.  What you do to your bike is your responsibility, so please proceed with care.

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