Two questions as I start down this road... Do you need the tool as described in the manual if you remove the tank? How difficult would you say changing the upper and lower covers out is? I am concerned about getting half way through this and only to find out I am over my head.

 

from what I understand, the worst part is the tank...

 

Removing the tank is easy, just messy if you don't have all the fuel out. I removed my rocker boxes and swapped out my pushrod tubes and lifter blocks without pulling the tank. Pulling the tank would have taken an extra 5 minutes at the beginning of the job, and probably saved me 20 minutes during the course of the job. If/when you pull the tank, install a quick-disconnect on the crossover.

 

If you don't go with the quick disconnect make sure you have a small hose clamp, If its the same as mine was, there was a one time use banded clamp on the crossover line. I went with a screw on type crossover line from J&P, pretty cheap and looks better. After you get the fuel out and the cross over line off, just take the front and rear bolt out and slide the tank back and up, comes right off.