HOW - TO: Assemble / Disassemble Fuel Tank Guts
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Outstanding HDF Member
Joined: Apr 2006
Posts: 2,555
Likes: 3
From: Clarksburg, PA
HOW - TO: Assemble / Disassemble Fuel Tank Guts
Since I am swapping my tins out, thought I'd give everyone an inside look at your FI gas tank.
This will help you to replace a fuel pump or bad sending unit also.
This is my second time to disassemble and reassemble so I is a x-spurt!
I took these pics when I reassembled my new tank, but I'll do the write up like I'm tearing it down for better understanding.
1. I actually leave the tank on the bike to disassemble the guts since it's easier for me to work on, but as stated, I was actually reassembling this tank.
2. Remove your Speedo, etc and disconnect the wiring and vent hose from the top plate.
3. Remove the T20 bolts...this is a Street Bob tank by the way.
4. The cover will not lift straight up, you have a vent tube (top of pic) so you have to turn sideways and bring to the left of the bike. Under the cover, disconnect the wires and remove the gasket...it's not glued in place.
5. I take the sending unit out first. it's on the right side and locks in place near the top of the tank...slide it backwards to remove it from the clips.
6. It comes out easily.
7. Here is the fuel pump in place. It will slide forward from the clips.
8. The hardest part for me is disconnecting the gas outlet hose. It is just a squeeze connector, but never works right! I actually pop the fuel pump off the clips before I disconnect this...I'm actually reassmebling as I write this though.
Make sure to put the O-RING on before assembly.
9. The only way I could get it out was to turn it 180°....use some finesse and be careful with it.
10. If you are swapping tanks, use a 7/8" wrench to remov the quick - disconnect / outlet hose.
10. There it is...all naked!
11. Here are your guts!
Something like this would have helped me out the first time I did it so maybe it will help someone else!
This will help you to replace a fuel pump or bad sending unit also.
This is my second time to disassemble and reassemble so I is a x-spurt!
I took these pics when I reassembled my new tank, but I'll do the write up like I'm tearing it down for better understanding.
1. I actually leave the tank on the bike to disassemble the guts since it's easier for me to work on, but as stated, I was actually reassembling this tank.
2. Remove your Speedo, etc and disconnect the wiring and vent hose from the top plate.
3. Remove the T20 bolts...this is a Street Bob tank by the way.
4. The cover will not lift straight up, you have a vent tube (top of pic) so you have to turn sideways and bring to the left of the bike. Under the cover, disconnect the wires and remove the gasket...it's not glued in place.
5. I take the sending unit out first. it's on the right side and locks in place near the top of the tank...slide it backwards to remove it from the clips.
6. It comes out easily.
7. Here is the fuel pump in place. It will slide forward from the clips.
8. The hardest part for me is disconnecting the gas outlet hose. It is just a squeeze connector, but never works right! I actually pop the fuel pump off the clips before I disconnect this...I'm actually reassmebling as I write this though.
Make sure to put the O-RING on before assembly.
9. The only way I could get it out was to turn it 180°....use some finesse and be careful with it.
10. If you are swapping tanks, use a 7/8" wrench to remov the quick - disconnect / outlet hose.
10. There it is...all naked!
11. Here are your guts!
Something like this would have helped me out the first time I did it so maybe it will help someone else!
Last edited by Mascman; Nov 10, 2008 at 04:03 PM.
Outstanding HDF Member
Joined: Nov 2007
Posts: 2,289
Likes: 22
From: Beautiful Downtown Burbank
thanks for the write up Mascman
I wonder if we can talk Mud into putting together a how-to section that actually makes sense. The manual is nice, but nothing beats advice from someone thats been there
I wonder if we can talk Mud into putting together a how-to section that actually makes sense. The manual is nice, but nothing beats advice from someone thats been there
Thread Starter
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Outstanding HDF Member
Joined: Apr 2006
Posts: 2,555
Likes: 3
From: Clarksburg, PA
I thought the inside may be a mystery to some so I figured while I'm doing it, why not take the pics?
I was a little nervous as those are all cell phone pics...taken while trying to hold the tank parts and take a pic with one hand.
My phone is hard to take pics with one hand! All I kept thinking was, "Please don't fall on the paint!".
After I get the top plate off, I take a hand siphon pump to get the gas out. It's quick and easier than trying to drain it from the crossover tube.
I was a little nervous as those are all cell phone pics...taken while trying to hold the tank parts and take a pic with one hand.
My phone is hard to take pics with one hand! All I kept thinking was, "Please don't fall on the paint!".
After I get the top plate off, I take a hand siphon pump to get the gas out. It's quick and easier than trying to drain it from the crossover tube.
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Wow, I love it when we get to see full color picks of the process. It always tells so much more than the Service Manual.
This just makes me want to start taking pics of the different steps of every mod i do...
Thanks again!
This just makes me want to start taking pics of the different steps of every mod i do...
Thanks again!