Putting the gas tank back in place

[jayshaw91]

Because stupid shit surfaces.

So I was about to do the TBS. Undid the two black clips by the seat, took out the two bolts that hold the tank down, then lifted.

Now, I set the tank back down and the holes for the bolts for the tank and the holes for the clips are all off by about 1/4 inch. All of the holes that the bolts/clips go through are too far back.

So now what? What the hell did I **** up? I can't seem to pull the tank forward or anything.

Signed,

Technically DEclined...

 

[skyway]

just push the rear of the tank forward to align the front bolts. No you haven't effed anything up. :lol:

 

[jayshaw91]

I tried that and it didn't seem to move anywhere. I guess I'll go try again.

Yes, I'm pissed off right now. Thanks for the very fast response.

 

[Ignacio]

So I was about to do the TBS. Undid the two black clips by the seat, took out the two bolts that hold the tank down, then lifted.

When you lifted you noticed it pivoted around a single bolt in the back? Loosen that bolt. I believe it has a 12mm nut on the right side. It makes it easier to line up the two bolts at the neck. Once those are down, snug it back up.

...at least on my 05.

 

[mdisher]

Yessir, two in the top go in first... Get them started All will be well.

Er, did you put the T-Bar in right, under in the middle and over at the top? Is this an 06?

 

[jayshaw91]

This is an 06. I can't even get the bolts to start. The holes are off by too much.

I didn't touch the T bar. I was checking how to remount the tank before I even got around to the TBS or anything. If I don't watch everything I do, I miss something later, so I do small steps at a time.

Ig, by chance do you have a pic? I think I know which bolt you're talking about, but at this point I don't want to make my life worse.

To boot, the tank is 3/4 full, so it's heavy as hell.

EDIT:

Ok, just went for it on the two bolts. Fairly obvious which ones. Thanks for the tip, Ig. And yes, 12mm bolt.

Any idea what the torque is for that nut? Looks like 11ft/lb according to the generic info on the FAQ. Just verifying it's not something different.

Yes, I need a maint manual. I think I'll put off the TBS until I have less gas in the tank just so it's lighter with less chance of crushing my hand(s).

 

[mdisher]

Seriously, take the rod out of the back...

Pick up the tank... Set the top down up top over the top front holes (gently) all will be well.

There's nothing there you're gonna hurt.

Gonna link to a pic in a sec.

OK, never mind you got it...

 

[Ignacio]

EDIT:Ok, just went for it on the two bolts. Fairly obvious which ones. Thanks for the tip, Ig. And yes, 12mm bolt.

Any idea what the torque is for that nut?

Shows as 11 ft./lbs. for my '05.

 

[Rogue]

The word at WFO was on the 06' the tank has to come compleatly off and you need 3 people to do a TBS on one.

I'm sure WC or someone who saw him do one can chime in.

 

[TheAxeman]

To get the holes aligned I use either a small screwdriver or an allen key put it through the fastener hole on the tank and into the hole on the bike and just pull it forward gently. That allows you to get one started and the other one goes in easily. If your worried about having to pry to much or bunging up the threads in the bolt hole than put a little electrical tape around the end of the screwdriver. Or....do like iggy says and loosen the pivot bolt at the bottom of the tank.

 

[pawtracks]

I helped Warchild do about 8-10 '05's at WFO, he did mention the '06 was a PITA compared to the '05.

A fuller tank makes it harder when it is only you, but not impossible.

Agree with all that the rear hinge/pivot bolt has to be loosened (but not removed) to align the top two near the stem.

You '06 owners, what's different?

Is it the heat shield blanket thingy that gets in the way.

Does the tank really have to come off (completely off) :blink:

 

[mdisher]

I helped Warchild do about 8-10 '05's at WFO, he did mention the '06 was a PITA compared to the '05.
A fuller tank makes it harder when it is only you, but not imposible.

Agree with all that the rear hinge/pivot bolt has to be loosened (but not removed) to align the top two near the stem.

You '06 owners, what's different?

Is it the heat shield blanket thingy that gets in the way.

Does the tank really have to come off (completely off) :blink:

Yes, you have to take the heat shield blanket OFF, and unplug the fuel pump, and gauge wires from the tank (which route through it) to take it off. I removed the bolt from the back of the tank, and really got the tank out of the way to do this.

I wouldn't necessarily call it a PITA though. But then I haven't done a pre-06. I have sync'd the carbs on my ZX-11 and that is a monumental pain in the ass compared to this. I'd rather to (10) 06 FJR's than one ZX11 any day.

 

[Ari Rankum]

I helped Warchild do about 8-10 '05's at WFO, he did mention the '06 was a PITA compared to the '05.
A fuller tank makes it harder when it is only you, but not impossible.

Agree with all that the rear hinge/pivot bolt has to be loosened (but not removed) to align the top two near the stem.

You '06 owners, what's different?

Is it the heat shield blanket thingy that gets in the way.

Does the tank really have to come off (completely off) :blink:

Depends on your definition of "off". Because of the plastic molding on the sides of the tank near the seat/pivot point extends beyond the kingpin on the 06, there's no way to lift the tank high enough without snapping them off, or removing the kingpin. I chose the latter option. So the '06 is moderately more a pain in the ass in that you have to remove the Jiffy-Pop and the kingpin and scootch the tank backward enough to mess around and get the TBS done. I didn't have to disconnect fuel lines or move the tank more than a few inches. I believe I've seen posts that suggest folks have done 06's by just propping the tank at the front and folding the Jiffy-Pop out of the way. That may be true, but, for me, making things visible up front probably saved some aggravation.

 

[PTP]

I helped Warchild do about 8-10 '05's at WFO, he did mention the '06 was a PITA compared to the '05.

A fuller tank makes it harder when it is only you, but not imposible.

Agree with all that the rear hinge/pivot bolt has to be loosened (but not removed) to align the top two near the stem.

You '06 owners, what's different?

Is it the heat shield blanket thingy that gets in the way.

Does the tank really have to come off (completely off) :blink:

Yes, you have to take the heat shield blanket OFF, and unplug the fuel pump, and gauge wires from the tank (which route through it) to take it off. I removed the bolt from the back of the tank, and really got the tank out of the way to do this.

I wouldn't necessarily call it a PITA though. But then I haven't done a pre-06. I have sync'd the carbs on my ZX-11 and that is a monumental pain in the ass compared to this. I'd rather to (10) 06 FJR's than one ZX11 any day.

+1

I've never sync'd a ZX11, but I just did my '06 FJR last weekend and never thought that it was that difficult. I pulled the tank off and set it on the floor away from the work area, removed t-bar, heat shield, got the carb sticks in place, set the tank loosely back in place allowing vacuum lines pleanty of room, then did the balance. Set the tank back on the floor and reassembled everything in reverse order. Sounds like a big production but it really isn't.

The biggest thing to remember is that gas tanks go on the floor when not in use...not on the work bench, not on a box, not on the top of the garbage can...don't learn the hard way.

PTP

 

[jayshaw91]

PTP, a little fule spillage, huh?

 

[chickey191]

One thing I noticed when someone was doing an '06 -- don't think it was dale as he already had a problem even saying "Throttle Body Sync" at the time - -

was...

someone removed their tank on the '06. Don't remember why they did - but they took it off. I think the added ease of being able to readily see the vacuum caps and easier access to them - probably made it worthwhile removing the tank. Since most of the work is already done - it doesn't present much additional effort.

With two people - you might just have one person LIFT the tank providing that easier access - then you don't have to worry about putting it on the floor and kicking it or disconnecting vacuum lines or anything else.

One thing that might be cool to do - don't know if it would work - would be to cut the jiffy pop appropriately - allowing it to be folded back. you would have to seal the cuts with something appropriate that would allow you to seal/re-seal frequently. giving you easier access to the throttle bodies. then you could just fold back without taking off the t-bar, etc.

Not sure that this would actually work, but it might be something to think about. How often do you have to do a tbs, anyway?

 

[Luke]

I have an '06, propped and tied the tank back, unfasten the electrical connectors and push them thru the foil, fold the foil back and tie it back, put the elctical connectors back on, then do the TBS. I made sure I had plenty of fuel in the tank so I could run the engine this way. No big deal.

Oh, and you do NOT have to remove the T-bar!

 

[Woodstock]

Oh, and you do NOT have to remove the T-bar!

I thought you had to remove the T-bar to remove the jiffy-pop, and that you had to remove the jiffy-pop to get to the vacum nozles?

 

[Luke]

I did it with the T-bar in place and jiffy-pop folded back towards the front of the bike over the T-bar. Held it back with a mini-bungee cord.