Removing tank

[MSLPILOT]

I'm removing the tank off my '04. Sending it in to get the dent fixed.

Anything I need to know before doing so? Anything I should be careful of? Anything I need to do before, during or after removal?

Also, what about reinstalling it? Same questions.

I'm not a mechanically inclined person, but I have changed out ceiling fans! :huh: And I think I stayed at a Holiday Inn once...

Thanks for any help.

 

[JimLor]

Removing the tank isn't a big deal. Need to release the black plastic curtains on the bottom, take off the 2 x bolts at the front - raise and prop up the tank (I use rope tied off to the rear rack) then remove the 2 x vent tubes (left side of tank), the 2 x electrical connectors; and the 2 x fuel lines. Gas won't leak from the tank, but you have to be carefull with the lines, some gas will leak out. I put a golf tee (clean) in the one line but the other has a 90 degree turn, so just be careful.

Lower the tank and remove the rear bolt/nut and lift the tank off.

Since you're taking the tank to be worked on, you'll have to get the gas out best you can!

This is an easy job!

 

[MSLPILOT]

Easy huh? :blink: What would take you 30 minutes will likely take me all day! Info is much appreciated though. Thanks Jimlor.

 

[Geezer]

Don't forget to loosen the bolt at the rear of the tank before you lift the front. You need to remove the seat to get to it.

Also, on the left side, where the bolt goes in that holds the tank in place, there is a rubber grommet which also serves as a hanger for a couple of hoses. Make sure you slip that off the tang on the tank before you lift the tank. It will probably come off as you lift but you want to be aware of it.

EDIT: - removed inaccurate information.

None of this is difficult and takes only a couple of minutes but you want to be careful and don't force anything.

 

[radman]

And, one more thing, it is easier to lift the tank if you remove the left and right rearmost dash panels.
None of this is difficult and takes only a couple of minutes but you want to be careful and don't force anything.

Actually, I do just the opposite-lift or remove the tank to ease removal of the panels. I use 1 or 2 bungees hooked on the rear rack (depending on fuel load) to support the tank, and I tape a towel (2" masking tape along the front edge of the tank) to protect against scratches etc. When lifting the tank, also be aware the wiring harness for the pump/fuel sender will be the limiter in how far the tank will raise-disconnect for more room. Note that both plugs are similar, a small piece of tape labeled "out" for the outside one will simplify reconnection.

 

[JimLor]

MSLPILOT - you're most welcome. It was daunting the first time I removed the tank and like Geezer said, don't force anything - just figure out why something won't move and you'll know better next time! Just break it down into the individual actions required and have at it!

 

[stryg8r]

Here's a great how to from FJRINFO. Nothing works better for me than pictures, and this is a very good writeup with plenty of pics. FJR INFO - How to remove the FJR's Gas Tank

You may want to take some reference pics of your own as your remove your tank. I find it easy to remove stuff, but much more difficult to put it back on. Luckily I haven't had any spare parts left over yet. Just take your time and it's an easy job.

After the tank is off you can just flip it over to drain the remaining fuel. Then let it air dry for a while. Compressed air will speed this up.

Derek

 

[radman]

Hmarc's guide is nice, but I'm surprised he still hasn't fixed the blurb near the end concerining the "vac line". It's a fuel return line, comes off of the fuel pressure regulator, and can and will have gas in it.

"The vacuum line has this little rubber boot over the metal retaining clip indicated by the red arrow above. First remove the boot, remembering how it went on, then use some pliers to squeeze the retaining clip and slide it away from the nozzle to allow the hose to be pulled straight off. Nothing will leak out of this hose either."

For those removing the gas cap assembly, be aware that the socket head screw inside the cap assembly at the rear is subject to major corrosion. I replaced with a stainless 5mm screw to prevent future problems there.

 

[Geezer]

(snip)Actually, I do just the opposite-lift or remove the tank to ease removal of the panels. (snip some more)

Yep, Radman is correct. Lift the tank to get the panels off, not the other way around. Haven't had my coffee yet this morning.

 

[MSLPILOT]

You guys are great. Thanks for all the help. You're making me feel more and more confident with each posting.