Gas Tank Removal
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Cruiser
Joined: Feb 2008
Posts: 195
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Gas Tank Removal
Curious how difficult it would be to remove the gas tank off of my '07 FXST. I know that the gas gauge and speedo may create the difficulty. Anyone willing to post a walk-through for me I'd appreciate it.
Removing the front and rear fenders is pretty self explanatory but it would look stupid to only paint those.
Removing the front and rear fenders is pretty self explanatory but it would look stupid to only paint those.
Stellar HDF Member
Joined: Nov 2005
Posts: 2,272
Likes: 10
From: Orange VA
RE: Gas Tank Removal
I scanned the service manual pages but uploading the the forum isn't working now. PM me with email and I'll shoot them to you.
It certainly helps to have pictures for reference but until I can get them posted, here's the narrative version...
It's not too hard. I found the biggest pain was cutting the OEM hose clamps on the crossover hose and draining the gas. Best case you can run the bike out of fuel before you start this.
Not sure why they have you disconnect the negative battery AFTER you pull the supply line off the tank - potentially spilling gas. I'd think there would be a risk of spark and I'd want to protect against that before pulling fuel lines off. (But who am I kidding, I just pull the maxi fuse and call it a day. Disconnecting the negative battery cable is kind of a pain.)
It certainly helps to have pictures for reference but until I can get them posted, here's the narrative version...
It's not too hard. I found the biggest pain was cutting the OEM hose clamps on the crossover hose and draining the gas. Best case you can run the bike out of fuel before you start this.
Not sure why they have you disconnect the negative battery AFTER you pull the supply line off the tank - potentially spilling gas. I'd think there would be a risk of spark and I'd want to protect against that before pulling fuel lines off. (But who am I kidding, I just pull the maxi fuse and call it a day. Disconnecting the negative battery cable is kind of a pain.)
Stellar HDF Member
Joined: Nov 2005
Posts: 2,272
Likes: 10
From: Orange VA
RE: Gas Tank Removal
[ol][*]Remove seat[*]Remove fuse box cover[*]Purge fuel line of high pressure gasoline[ol][*]See fig 4-4. (When I can get you the scanned pages) Disconnect the fuel pump fuse from the main harness.[*]Start the engine and allow vehicle to run[*]When it stalls, operate starter for 3 seconds to remove any remaining fuel from fuel lines.[/ol][*]See fig 4-5. Pull up on chrome sleeve of quick connect fitting (1) and pull down on fuel supply line (2) to disconnect. (This is on left side of tank just above rear spark plug)[*]Disconnect negative battery cable.[*]Remove instrument console. See fig 4-6. Remove acron nut (1) and washer (2) from console to separate console from fuel tank.[*]Disconnect console wiring[*]See fig 4-7. Unplug fuel module connector (86). (This is the last connector on the tank under where the console was mounted)[*]Drain fuel tank[ol][*]Get a short section of 5/16 ID hose. Plug one end[*]Cut clamp from one end of cross over hose (above front cylinder). Pull one side of cross over hose off fitting and quickly replace with your plugged piece of hose. Direct cross over hose into a container to catch fuel.[/ol][*]Remove the tank (see fig 4-9)
[ol][*]Remove rear Torx screw and washer (T40)[*]Remove Acorn nut, washers, and front mounting screw[*]Remove continuous vent line from nipple on front of tank (front top center, just above the frame tube)[*]Disconnect fuel guage connector (located under left side of fuel tank) (small black connector)[*]Remove tank from motorcycle. Remove rubber trim and bushings/grommets if necessary.
[/ol][/ol]
[ol][*]Remove rear Torx screw and washer (T40)[*]Remove Acorn nut, washers, and front mounting screw[*]Remove continuous vent line from nipple on front of tank (front top center, just above the frame tube)[*]Disconnect fuel guage connector (located under left side of fuel tank) (small black connector)[*]Remove tank from motorcycle. Remove rubber trim and bushings/grommets if necessary.
[/ol][/ol]
Tourer
Joined: Oct 2007
Posts: 292
Likes: 0
RE: Gas Tank Removal
It is not hard. I just got done doing it and the only part that sucked was when I pulled the crossover line off and was trying to drain the gas I spilled it all over me so I stunk like gas. After that it was a cake walk.
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