|  | Topic : Fuel Tank Removal |  |
| | | EnGage | | Thor |  |  | | Reg. Date | : | 14/07/2009 | | Posts | : | 3,155 | | Location | : | Grand Rapids, MI, United States |
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| | Posted : 13 Aug 2011 - 13:38 Post title : Fuel Tank Removal | | | So here is the procedure:
1. Remove the three bolts holding on the instrument cluster and set aside.
2. Lift the cluster off the tank and rotate it upside down. Pull back the rubber gasket around the wiring harness to access the relief pin on the harness. Press the relief pin and pull the connector out. Put the cluster aside. (note - putting a soft towel over the tank while doing this is a good idea).
2. Remove the front tank bolt and remove the nut from the back hinge bolt, but leave the hing bolt in place.
3. Remove the instrument cluster harness from the retainer on the tank.
4. Lift the tank up from the front. I use a roll of paper towels with about 60% left to hold up the tank. Works nice.
5. Remove the two wiring harnesses
6. Remove the vent tube and pull it out of the retainers.
7. Remove the fuel line. It took a minute to figure this out, but there is a blue plastic clip around the fuel line where it connects to the tank. It will slide down (but not off) revealing two buttons (one on each side). Slide the blue clip down, get both hands under the tank and press these buttons in. The fuel line should pop off. There may be a bit of gas that come out from the top of the line.
8. remove the rear hinge pin (bolt) - I believe you will need to angle the tank up more to clear the hinge - pull off the tank.
If you have T bars, like me, the tank will not clear the bars and you must remove the back hing bolt, grab the tank and lift the tank backwards. I haven't tried this yet, but I image one could wrap the bars with a towel, pull the tank back to clear the bars and then reinsert the hing bolt and rest the tank on the bars. You could then disconnect everything under the tank. I'll have to try this, but the last two times I have had my wife hold the tank.
| | Post edited by EnGage on 13 Aug 2011 - 13:40 |
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| | | DizzE | | Thor | |  | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 20 Aug 2011 - 13:44 Post title : Re: Fuel Tank Removal (Re: EnGage) | | | Just wanted to add a picture to this excellent write up. The 3 tricks to the tank....at leaast for me.
On the left is the fuel line that Engage talks about. Pull blue cover back, reveal a pair of pinch buttons.
Middle is instrument cluster. Fold back the rubber boot.
On right are two electric connections. Unlike a lot of computer connections, these pinch at the "top."
And the little black one has a piar of little pinchers that pinch in together from the top..
This stuff is hard to see and figure out when you have the tank half up and balanced on the bars.
BTW, I'm using the Duece risers, so I always pull the hinge pin first. Then I rest the tank on an old pillow and handlebars.
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| | | GerPa | | Jupiter | |  | | Reg. Date | : | 10/12/2011 | | Posts | : | 1,919 | | Location | : | Mackay, Central Queensland, Australia |
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| | Posted : 26 Jan 2012 - 02:12 Post title : Re: Fuel Tank Removal (Re: DizzE) | | | I have heard that if you remove the fuel tank and disconnectthe Instrument Cluster that you end up having the Engine Management light on when you reconnect everything.Is this correct? then you have to take the bike back to the dealer to get the ECU reset.
Rgds
Gerry D
|  May-2011-1600, 20306 Tune, Mustang Vintage Solo Seat, Meerkat Cat Bypass, + Meerkat Modified Short TORS   ,K&N Air Cleaner,K&N Oil Filter, JBQ lifting system, Gold Plug Magnetic Sump Plug,Dart Fly screen, Rivco Risers, GiPro Gear Indicator, Breakaway Cruise Control, Avon ISO Grips, Scorpion Western Low Handlebars, Kury Switchblade Pegs, Garmin Zumo390LM,Michelin RC2 on Front RC 3 on ,Modified Rear Drive Pulley Hub Bearings (Mat1600/Alex4 Modification) Front Susp: Std & 7.5W Oil /126mm Air Gap & Rear:Hagon Nitro's with 26Kg/cm Springs + Lots of other "Bling" stuff.
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| | | FTL40 | | Jupiter | |  | | Reg. Date | : | 13/10/2009 | | Posts | : | 1,122 | | Location | : | massachusetts, United States |
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| | Posted : 26 Jan 2012 - 02:33 Post title : Re: Fuel Tank Removal (Re: GerryD01) | | | only if you turn the key on. the ecu will reset itself after a bit of riding
| 2010 tbird 1700 silver (fastest color) BC exhaust, BC airbox removal
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| | | davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 26 Jan 2012 - 05:03 Post title : Re: Fuel Tank Removal (Re: FTL40) | | | Engage's last post with an explanation of his fuel tank removal procedure along with the pictures provided by DizzE, which further enhanced Todd's fuel tank procedure,got me thinkin.Good job btw,guys.  There's a lot of excellent information about the Thunder Bird on this site with some excellent pictures to accompany that info.It's too bad there isn't a section or library,if you will,dedicated to that information and or pictures for all members and guests to easily reference regarding their Birds,whether it be a repair,trouble shooting,or just adding an accessory.All you'd need is a guy that has computer savy and the ability to transfer any info and or pictures into that section.Whada you guys think??? Dave!!!
| | Post edited by davetac1 on 26 Jan 2012 - 05:23 |
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| | | easyrider | | Thor | |  | | Reg. Date | : | 17/12/2011 | | Posts | : | 2,066 | | Location | : | NSW, Australia |
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| | Posted : 26 Jan 2012 - 08:53 Post title : Re: Fuel Tank Removal (Re: davetac1) | | |
davetac1 wrote:
Engage's last post with an explanation of his fuel tank removal procedure along with the pictures provided by DizzE, which further enhanced Todd's fuel tank procedure,got me thinkin.Good job btw,guys. There's a lot of excellent information about the Thunder Bird on this site with some excellent pictures to accompany that info.It's too bad there isn't a section or library,if you will,dedicated to that information and or pictures for all members and guests to easily reference regarding their Birds,whether it be a repair,trouble shooting,or just adding an accessory.All you'd need is a guy that has computer savy and the ability to transfer any info and or pictures into that section.Whada you guys think??? Dave!!! |
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| | | Hornet | | Jupiter | |  | | Reg. Date | : | 05/05/2013 | | Posts | : | 1,294 | | Location | : | United States |
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| | Posted : 18 Jun 2015 - 11:49 Post title : Re: Fuel Tank Removal (Re: easyrider) | | | Gentlemen, good info here. How do you drain the excess fuel from the tank if you plan to replace the fuel filter pump etc?
| You'll never be first but you might be next
2014 Commander
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| | | Neb127 | | Set | |  | | Reg. Date | : | 02/04/2015 | | Posts | : | 26 | | Location | : | Seattle, WA, United States |
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| | Posted : 18 Jun 2015 - 19:20 Post title : Re: Fuel Tank Removal (Re: Hornet) | | | Hope you get an answer to this - because it's just what I need to do
is the filter in the tank or in-line ?
| 2010 (the fastest year) - BC Preds and some flashy LEDs things on mirrors
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| | | Hornet | | Jupiter | | | | Reg. Date | : | 05/05/2013 | | Posts | : | 1,294 | | Location | : | United States |
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| | Posted : 18 Jun 2015 - 20:03 Post title : Re: Fuel Tank Removal (Re: Neb127) | | | Inside the tank, along with the pump and regulator. Here's a good youtube on a Bonneville, the process would be the same.
https://www.youtube.com/watch?v=-5XOoiRWkKg
| You'll never be first but you might be next
2014 Commander
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| | | kiwitrumpy | | Set | | | Reg. Date | : | 04/06/2015 | | Posts | : | 15 | | Location | : | New Zealand |
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| | Posted : 20 Jun 2015 - 00:55 Post title : Re: Fuel Tank Removal (Re: Hornet)I support | | |
I support Daves idea of a libary ..I am not computer savy but I thought it could bee set up similar to the way we look at members pictures that members post.ie alphabetically.There is so much knowledge on this web site and even myself has asked questions that have been previously answered, even after scrawling through pages.I have at times googled questions and it directs us to the forum also.
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| | | peteronkarra | | Chaac | |  | | Reg. Date | : | 01/04/2012 | | Posts | : | 830 | | Location | : | Karragarra Island, Queensland, Australia |
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| | Posted : 21 Jun 2015 - 21:56 Post title : Re: Fuel Tank Removal (Re: Hornet) | | |
Hornet wrote:
Gentlemen, good info here. How do you drain the excess fuel from the tank if you plan to replace the fuel filter pump etc? |
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I just drained it by syphoning the fuel out with a hose into a clean container before I started.
You don't need to fully drain the tank to do the fuel filter but fuel can be forced out of the breather/overflow pipes as you seal it back up while the tank is on its back.
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| | | DrMooman | | Set | | | Reg. Date | : | 09/08/2016 | | Posts | : | 73 | | Location | : | Wales, Wales, United Kingdom |
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| | Posted : 01 Sep 2016 - 06:55 Post title : Re: Fuel Tank Removal (Re: EnGage) | | | If anyone wants a more comprehensive guide see my site
Link
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,485 | | Location | : | Australia |
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| | Posted : 01 Sep 2016 - 09:49 Post title : Re: Fuel Tank Removal (Re: peteronkarra) | | | I just stand mine up on it's end on the workbench, leaning on a towel against the backboard, after syphoning off any excess.
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1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Hagon Nitro shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | VABird | | Jupiter | |  | | Reg. Date | : | 28/09/2014 | | Posts | : | 1,373 | | Location | : | BEDFORD, Virginia, United States |
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| | Posted : 01 Sep 2016 - 12:10 Post title : Re: Fuel Tank Removal (Re: Leethal) | | | Nice write up. The first time I went to remove the tank, I stopped just shy of disconnecting the fuel line, not certain that it all wouldn't run out.
I was able to do what I needed to by just lifting it a bit, but still, great to know.
| The ride may be fun, but in the Great Scheme of things, it really is about the destination! John 3:16
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| | | davetac1 | | Thunderbird | | | Reg. Date | : | 06/09/2010 | | Posts | : | 8,379 | | Location | : | Haverhill, Ma., United States |
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| | Posted : 01 Sep 2016 - 13:08 Post title : Re: Fuel Tank Removal (Re: VABird) | | | I've had my tank off twice [in the six years I've owned this machine] to replace the fuel filter inside.However ,on the 2nd filter change,I also replaced that big rubber gasket because I don't want any surprises [ leaks] while goin down the road.  And DO NOT OVERTIGHTEN those screws that secures that rubber gasket cause that will crush it,hence,start leaking.
Other then that,I've had it tipped up so as to change my plugs [I change em every 25,000 miles],and to replace those MAP sensor plastic lines with the newer upgraded ones.What ya gotta remember if ya remove and or tip the tank up, is not to forget to put the little vent hose back on underneath it,otherwise you'll have gas all over the place.Don't ask how I know!  But a good tip is,allow the tank to run down on fuel,or syphon it out "BEFORE" ya remove or tilt it up.Believe me,it'll make life a whole lot easier for ya!! Dummy Dave!!!
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