Fuel Tank - Removal

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.

Warning - General - Fuel

warning
Observe the warning advice given in the General Information section on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.
warning
Never drain fuel from the tank using non-approved, non-professional standard fuel handling equipment. A fire causing destruction of property and injury to persons may result from use of non-approved fuel handling equipment.

Fuel Tank Removal - Quick Release Tank Bag

warning
For models fitted with an accessory quick release tank bag only:The fuel must be drained from the fuel tank before removal.The fuel filler cap will be loose after removing the accessory tank bag quick release ring.A fire, causing personal injury and damage to property could result from spilled fuel or fuel not handled or stored correctly.
notice
For models fitted with an accessory quick release tank bag only:The quick release ring must be removed before removing the fuel tank. Please refer to the relevant accessory fitting instruction for details.Using proprietary professional automotive workshop equipment approved for fuel handling, drain the fuel from the fuel tank.

Perform the following operations

Perform the following operations:

Seat - Remove L Series

Battery - Remove L Series

Side Panels - Removal LG1; LG2; LGX; LH2

Fuel Tank Remove LG1; LGX

  1. Unclip and remove the ignition barrel shroud from the fuel tank.
    2. Fuel Tank Front Panel_1 (cktz)

    1. Ignition barrel shroud

  2. Remove the rear and side fixings from the fuel tank bodywork.
    3. Fuel Tank Rear Fixing (ckuf)

    1. Fuel tank bodywork

    2. Rear fixing

    3. Side fixing (right hand side shown)

  3. Remove the front fixings from the fuel tank bodywork.
    4. Fuel Tank Front Fixings (cktx)

    1. Front fixings

  4. Flex the fuel tank bodywork sides out in the areas shown below and lift clear of the fuel tank.
    5. LG1 Fuel Tank Flex

    Fuel tank flex positions

  5. Unclip the twist grip position sensor harness connector from the fuel tank bracket.
    6. Twist Grip Position Sensor LG1 (ckyk)

    1. Twist grip position sensor main harness connector

    2. Twist grip position sensor connector

  6. Release and discard the two fixings and remove the immobiliser module from its bracket.
    7. Immobiliser_1 (ckum)

    1. Immobiliser module

    2. Fixings

  7. Release the three fixings and remove the immobiliser bracket from the frame. Allow to rest to one side.
    8. Immobiliser Bracket_1 (ckul)

    1. Immobiliser bracket

    2. Fixings

  8. Unclip the left hand switch housing connector A (2) and the right hand switch housing connector (1) from the fuel tank.
  9. Disconnect the ignition switch electrical connector.
    10. Fuel Tank LH Connections (ckuc)

    1. Right hand switch housing connector

    2. Left hand switch housing connector A

    3. Left hand switch housing connector B

    4. Fuse box 2

    5. Ignition switch connector

  10. Release the two fixings and remove the harness bracket from the frame and allow to rest to one side.
    11. Fuel Tank LH Bracket (ckub)

    1. Fixings

    2. Harness bracket

  11. Remove the two front fixings and flanged sleeves from the fuel tank.
    12. Fuel Tank Front Fixings (ckty)

    1. Fixing (right hand side shown)

    2. Flanged sleeve

  12. Remove the lower fuel tank bracket fixings.
  13. Loosen, but do not remove, the upper fuel tank bracket fixings.
    14. Fuel tank rear bracket (ckue)

    1. Upper bracket fixing (left hand side shown)

    2. Lower bracket fixing (left hand side shown)

    3. Fuel tank rear bracket

  14. Tilt the fuel tank and bracket assembly rearwards to allow access to the fuel tank electrical connectors and hoses.
    15. Fuel Pump Connectors (cktw)

    1. Fuel level sensor electrical connector

    2. Fuel pump electrical connector

    3. Fuel tank

    4. Fuel hose

  15. Disconnect the fuel pump and fuel level sensor electrical connectors.
    16. warning
    If the fuel rail is dismantled without first reducing pressure, fuel may escape causing clothing and components to be coated with fuel.This would represent a serious fire hazard which could lead to burn injuries and damage to property.
    note
    Because fuel stored in the fuel rail will be at 3.5 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump disconnected.When disconnected, the fuel tank is self-sealing but a small amount of fuel may dribble from the hose.
  16. Reconnect the ignition switch electrical connector.
  17. Have an assistant reconnect the battery, positive (red) lead first, and crank the engine to reduce pressure in the fuel rail.
  18. Disconnect the battery, negative (black) lead first.
  19. Disconnect the ignition switch electrical connector.
  20. Ease the latch away from the connector until the release buttons are exposed.
    21. Fuel line double check clip cekp_1

    1. Locked position

    2. Unlocked position

  21. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel pump plate.
    22. note
    Before disconnection, note the position of the two breather hoses so that they can be returned to the same locations when refitting the tank.
  22. Disconnect the two breather hoses from near the rear of the fuel tank and note their position for installation.
  23. Remove the upper bracket fixings and remove the fuel tank and bracket assembly from the motorcycle.
  24. If required, remove the pivot fixings and remove the bracket from the fuel tank. Discard the lock nut.
    25. note
    If fitting a new fuel tank, the barrel lock must be removed from the original fuel cap and fitted to the new one (see Fuel Cap Lock - Removal, Fuel Cap Lock - Installation).