Removing Gas Tank
Thread Starter
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Outstanding HDF Member
Joined: Oct 2006
Posts: 2,183
Likes: 1
From: Lenexa, KS (KC)
Removing Gas Tank
I need to replace my main wiring harness -- bad signal wire going to the tach. I'd just as soon do this myself but have never removed the gas tank.
How big a deal is it to remove the tank and what do I need to watch out for?
How big a deal is it to remove the tank and what do I need to watch out for?
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
RE: Removing Gas Tank
I have not removed mine but raised it up and backto check the stabilizer on top.
All you need to do is remove the seat,tank consol,over flow line,tank mounting bolts,fuel gage wire, the fuel cross over line, the main fuel line.Best to do with an empty tank and do this away from sparks,water heater,etc-.
If your not sure,a manual will help a lot.
All you need to do is remove the seat,tank consol,over flow line,tank mounting bolts,fuel gage wire, the fuel cross over line, the main fuel line.Best to do with an empty tank and do this away from sparks,water heater,etc-.
If your not sure,a manual will help a lot.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
RE: Removing Gas Tank
It's not difficult to remove the gas tank. I had mine off not long ago--used the Service Manual since it was my first time, and alsowanted the torque values for reinstallation. The only tips I can offer is to run down the amount of gas in the tank so there is a minimum to drain since the crossover tube in front of the tank is cut in the process and while the SM provides a plugging procedure, I decided to simply drain the tank.
Also, Dawg has a link to a quickdisconnect coupling to use when replacing the crossover tube that is a very useful feature in the event the tank needs to be removed in the future.
Also, Dawg has a link to a quickdisconnect coupling to use when replacing the crossover tube that is a very useful feature in the event the tank needs to be removed in the future.
Road Master
Joined: May 2006
Posts: 1,229
Likes: 20
From: Greater St Louis, MO
RE: Removing Gas Tank
It is not difficult, the less gas the better. It is pretty straight forward, just make sure you disconnect the fuel line when you start or you will break the plastic connection.
RE: Removing Gas Tank
The manual is pretty clear on the procedure. Only problem I had was the rubber seal around the filler tube. Can't seem to get it to seal properly. Anyone has any "tricks" for that. The manual doesn't say much about that.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
RE: Removing Gas Tank
ORIGINAL: IAMSWUTIAMS
The manual is pretty clear on the procedure. Only problem I had was the rubber seal around the filler tube. Can't seem to get it to seal properly. Anyone has any "tricks" for that. The manual doesn't say much about that.
The manual is pretty clear on the procedure. Only problem I had was the rubber seal around the filler tube. Can't seem to get it to seal properly. Anyone has any "tricks" for that. The manual doesn't say much about that.
Thread Starter
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Outstanding HDF Member
Joined: Oct 2006
Posts: 2,183
Likes: 1
From: Lenexa, KS (KC)
RE: Removing Gas Tank
Thanks everyone for the good tips! I've got a service manual but it doesn't seem that clear, or maybe it's just me. I'll go back and read it again a few times before attempting it. Sounds like the crossover tube get's trashed, so will need another? I'll send Dawg a PM for his quick disconnect link. Don't know what there is about doing this, but I'm more hesitant to remove the tank than I was to install the 26G's. Thanks again, fellas. 
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Road Master
Joined: Oct 2007
Posts: 813
Likes: 1
From: REPUBLIC of TEXAS
RE: Removing Gas Tank
i think you are to pull your fuel pump fuse then run it till it dies. to bleed off fuel pressure..
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Road Master
Joined: Jan 2006
Posts: 1,200
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From:
RE: Removing Gas Tank
Disconnect fuse or battery.
Disconnect main gas supply line - push up on the chrome sleave.
Remove console top (three bolts (one in the back, two under the gas cap door)
Remove rear tank bolt.
Remove left and right tank bolts (on front ears)
Cut hose clamp on left side of crossover tube
Will need a piece of extra hose with a plug in it (this to slide on the tank once you pull the crossover tube)
Will also need something to plug the other end of the crossover hose (once it's removed)
VERY quickly, will need to pull the crossover tube and qucikly install your plug in the open end of the cross over tube and then slide on the small piece of hose (with its plug as well) on the tank. I also put some tags under the tank to help catch the leaking gas.
Suppose you could also rig up something to drain the two tank halves one you disconnect them.
As you can tell once the crossover has been disconnected from the left side, the tank can then be lifted up and off.
Disconnect main gas supply line - push up on the chrome sleave.
Remove console top (three bolts (one in the back, two under the gas cap door)
Remove rear tank bolt.
Remove left and right tank bolts (on front ears)
Cut hose clamp on left side of crossover tube
Will need a piece of extra hose with a plug in it (this to slide on the tank once you pull the crossover tube)
Will also need something to plug the other end of the crossover hose (once it's removed)
VERY quickly, will need to pull the crossover tube and qucikly install your plug in the open end of the cross over tube and then slide on the small piece of hose (with its plug as well) on the tank. I also put some tags under the tank to help catch the leaking gas.
Suppose you could also rig up something to drain the two tank halves one you disconnect them.
As you can tell once the crossover has been disconnected from the left side, the tank can then be lifted up and off.