I need to remove my tank to get some more length in the RH electrical cables (doing a swap to a wider set of bars, FXST).

Has anyone, that has done this before on this model, got any instructions or tips ?

I would appreciate it.

Well I don't know if there is any difference to the 07 model so this is what I have to do to remove my fxd tank

1. empty your tank - you must do this, it is not very safe trying to remove it with any fuel in it, best to ride the bike till the tank is nearly empty before you start

2. remove the side cover on the left side and locate the fuse for the fuel pump

3. start the bike and with the bike running, pull the fuel pump fuse, this lets the bike use up all the fuel in the fuel line, this is how the manual say to do it.

4.. when the bike dies, kill the ignition switch ,with the key turned on disconnect the battery, this has to be done to stop the alarm going off when disconnecting the battery, after disconnecting the battery turn it off, replace your fuse.

5. discconect the main fuel line,it is a simple snap connector lift the chrom ring up and it will disconnect

6. undo the tank bolts and remove them.

7. remove the center trim and disconnect the two wiring harness and the breather line.

AND NOW COMES THE FUN- do this step at the very last moment

8. to remove the balance line at the front of the tank, you need three hands and do this where making a mess isn't important. I found using a very small G clamp to clamp the rubber hose and disconnect one side and then put your finger over the spout to block it , you can then remove the tank, put the hose back on when the tank is clear of the bike.

It is a pain in the ass

 

Just one hint , when putting back on, don't use loctite on the screws on the center trim, I did and when I went to remove them again, the loctite didn't give, the brass inserts in the plastic did, the inserts spun instead of undoing

 

this should give you some idea of what is involved

Thanks very much for your advice black29d.

I'm pretty sure tha set up on your07 model is exactly the same.

A few questions though:

(1) Did you have to do this because you were changing your bars? Did you manage to find excess wiring under the tank which would allow fitment of wider bars ?

(2)Where is the main fuel line connector ?

(3) Does the fuel filler cap and surround come up with the certre trim ? If not, what happens to that ?

(4) Do I have to destroy the crimped clamp on the balance line when removing one end ?

(5) Where is the fuel pump located ?

I appreciate your help.

If anyone else has any additional hints please feel free to contribute.

Ozroder

Stage 1 Poster
Posts:86

Nigeria
30 Sep 2008 3:48 PM Quote Reply Alert


If you want to do a good job take off the tank.................It will take you around 5 minutes tops to remove tank.........................

Rear button head bolts, front lower main tank bolts..........................2" pieice of 3/8 hose with clamp and bolt or lage screw stuck in other end and 2.5 feet of 3/8 hose and a bucket to drain fuel.................

I remove main tank bolt, get the wife to help me fit tank drain hose and plug hose for crossover hose under tank, then I unplug fuel line..........(simply pushdown on chrome fitting and it will disconnect)

Remove rear button head screw

Remove fuel sender wire

Gently rock tank back and forth and its off.....................................Ozroder

the fuel filler cap suround, there is only three screws around the ring that goes all the way into the top, the screw at the top (front of the bike)  and two either side on the bottom, the rest can be left alone and it will come off intacked with the trim, remove the cap then put it back on when you remove the trim.

the fuel pump and the fuel filter is inside the tank

the gasket for the tank top if you remove it to get to the fuel pump or filter is about $120....bloody highway robbery for a piece of molded rubber gasket... but you don't need to to take the tank off

 

Thanks guys

There are 4 cap head screws aroung the fuel gauge - do I have to remove them also ?

Do I have to remove any of the srcews arround the filler cap ?

 

this is were the 2 manuals come in, all will be explained...

Yes it pays to remove those screws, they screw into the plastic hosuing that holds the fuel gauge in place.

By the way fellas, I found out that removing the fuel tank was a waste of time anyway; it didn't help in getting to the wiring at all. It was virtually imopossible to get to the wires withing the chassis backbone.

I ended up just pulling on the two sets of cabling (which exit the chassis hole on the RHS) that I needed to extend and I managed to get the 15mm or so that I needed.

 

Thank for you help anyway guys. The couple of lengths of 3/8 hose helped a lot. Placing rags over the engin was important as you can't help spilling some of the fuwl when you pull one end of the ballance hose off. Did it by myself by the way .

Getting to the fuel gauge connector was tricky, though because it was underneath the tank and impossible to get to; I had to lift up the tank, turn it 180 degrees, place it on a small rubbish bin and then disconnect the connector .

Good experience though