Fuel Tank - Installation

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.

Fuel Tank Install LG1; LGX

  1. If required, assemble the fuel tank bracket to the fuel tank and secure with a bolt and new lock nut. Tighten the lock nut to 8 Nm.
  2. Align the fuel tank and bracket assembly to the frame and loosely fit the two upper bracket fixings.
    3. Fuel tank rear bracket_upperfixing (ckud)

    1. Fuel tank bracket

    2. Bracket upper fixing (right hand side shown)

  3. Tilt the fuel tank rearwards and refit the breather hoses as noted during removal.
  4. Refit the fuel pump and fuel level sensor electrical connectors.
    5. note
    The fuel hose has different coloured connectors on each end, to aid orientation. The grey end must be fitted to the fuel tank, the orange end must be fitted to the fuel rails.
  5. Reconnect the fuel feed hose by gently pushing inwards until the hose engages with a click.
  6. Slide the double check latch down (towards the spigot) until the release buttons are covered. If the latch will not slide into position, then the fuel hose is not fully home on its spigot and must therefore be refitted correctly.
    7. Fuel Pump Connectors (cktw)

    1. Fuel level sensor electrical connector

    2. Fuel pump electrical connector

    3. Fuel tank

    4. Fuel hose

  7. Lower the fuel tank and align the two front fixing holes.
  8. Install the two front fixings and flanged sleeves. Tighten to 9 Nm.
    9. Fuel Tank Front Fixings (ckty)

    1. Fixing (right hand side shown)

    2. Flanged sleeve

  9. Loosely fit the two lower bracket fixings.
  10. Tighten the right hand side upper bracket fixing to 12 Nm.
  11. Tighten the right hand side lower bracket fixing to 12 Nm.
  12. Tighten the left hand side upper bracket fixing to 12 Nm.
  13. Tighten the left hand side lower bracket fixing to 12 Nm.
    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. Refit the harness bracket to the frame with two fixings and tighten to 5 Nm.
    15. Fuel Tank LH Bracket (ckub)

    1. Fixings

    2. Harness bracket

  15. Reclip the left hand switch housing connector A (2) and the right hand switch housing connector (1) to the fuel tank.
  16. Reconnect the ignition switch electrical connector.
    17. 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

  17. Refit the immobiliser bracket to the frame with three fixings and tighten to 3 Nm.
    18. Immobiliser Bracket_1 (ckul)

    1. Immobiliser bracket

    2. Fixings

  18. Refit the immobiliser module with two new fixings and tighten to 1.5 Nm.
    19. Immobiliser_1 (ckum)

    1. Immobiliser module

    2. Fixings

  19. Reattach the twist grip position sensor harness connector to the fuel tank bracket.
    20. Twist Grip Position Sensor LG1 (ckyk)

    1. Twist grip position sensor main harness connector

    2. Twist grip position sensor connector

  20. Flex the fuel tank bodywork sides out slightly at the positions shown below and refit the fuel tank bodywork to the fuel tank.
    21. LG1 Fuel Tank Flex

    Fuel tank flex positions

  21. Install the two front fixings and tighten to 3 Nm.
    22. Fuel Tank Front Fixings (cktx)

    1. Front fixings

  22. Refit the two bodywork side fixings and tighten to 3 Nm.
  23. Refit the fuel tank bodywork rear fixing and tighten to 3 Nm.
    24. Fuel Tank Rear Fixing (ckuf)

    1. Fuel tank bodywork

    2. Rear fixing

    3. Side fixing (right hand side shown)

  24. Make sure the clips and rubber grommet are fitted and install the ignition barrel shroud to the front of the fuel tank.
    25. Fuel Tank Front Panel_1 (cktz)

    1. Ignition barrel shroud

  25. Using proprietary professional automotive workshop equipment approved for fuel handling, refill the fuel tank with the fuel previously removed.

Perform the following operations

Perform the following operations:

Side Panels - Install LG1; LGX

Battery - Install L Series

Check for Fuel Leaks

  • Start the engine and check carefully for fuel leaks. Rectify as necessary.

Seat - Install L Series