Sylvie Willis
Removing the gas tank from a motorcycle is often a last resort when attempting to resolve a fuel issue. However, it is a fairly easy process and a necessary step for many motorcycle repairs. Before removing the gas tank, it is important to secure your motorcycle on stable ground, remove the fuel, and disconnect the fuel pump and clear gas lines. Depending on the type of motorcycle, you may also need to remove the fairing, seat, and tank straps. Finally, remove the tank bolts and carefully lift the tank away from the bike.
How to remove a fuel flap from a motorcycle gas tank
| Characteristics | Values |
|---|---|
| Step 1 | Secure the motorcycle on a kickstand, lift, or wheel stands to ensure it doesn't tip over. |
| Step 2 | Remove the fuel by running it down, siphoning it out, or using a shop vac. |
| Step 3 | Disconnect the fuel pump and clear gas lines. |
| Step 4 | Remove fairings, the seat, and any tank straps, if necessary. |
| Step 5 | Remove the tank bolts but leave the tank in place. |
| Step 6 | Disconnect the main fuse for safety. |
| Step 7 | Remove the petcocks to get the last bits of gas out. |
| Step 8 | Wash out the tank with water to remove any fuel traces. |
| Step 9 | Use a saw to cut along the weld line, protecting your hands with gloves. |
| Step 10 | Push down the flapper with a screwdriver and pull out the cut section. |
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What You'll Learn
Secure your motorcycle on solid ground or a lift
To secure your motorcycle on solid ground or a lift, there are several options available. Firstly, it is important to understand the weight and balance of your motorcycle. Big cruisers and tourers are heavy bikes, and some lifts may not have the capacity to handle them. You should also know your bike's wet weight, which includes the weight of any accessories, to ensure the lift can support the load.
Motorcycle lift tables are a common method for securing a bike. These lifts vary in terms of power type, size, lifting height, and available accessories. When using a lift table, it is crucial to prepare the lift and the motorcycle. Attach straps or soft loops to the bike's handlebars, and ensure the wheel vise is set to the proper width to accommodate the front wheel. Lower the lift to the floor, secure the ramp, and slowly wheel the bike onto it. Secure the wheel vise, attach ratchet straps to tie-down points, and tighten the straps until tension is felt on both sides, keeping the bike level.
Other types of lifts include scissor jacks, which can lift bikes with flat or uneven lifting surfaces, and hydraulic lifts, which are more secure and reliable. When using a hydraulic lift, place it securely against a flat surface along the belly of the motorcycle to avoid damage. Use the foot pedal to raise the bike, and ensure it is not lifted to its maximum height. Secure the bike with straps, maintaining balance and avoiding scratches.
If you are securing your motorcycle on solid ground, there are several precautions you can take to prevent theft. Ground anchors are recommended and can be permanently bolted to the ground or temporarily screwed into dirt. Chains and locks can also be effective, but they must be set up correctly. Avoid letting the chain drag on the ground or simply slipping it through the wheel. Instead, tether the chain to a heavy, secure object, such as a street lamp, and wrap it multiple times to reduce slack. Always lock your motorcycle, and consider keeping it covered and out of view of potential thieves. Customization may also make your bike less desirable to thieves, as it is more easily identifiable.
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Disconnect the fuel pump and clear gas lines
To disconnect the fuel pump and clear the gas lines, you must first relieve the pressure in the fuel lines. The fuel lines within your fuel system are pressurised, so relieving this pressure is crucial before disconnecting any hoses. This can be done quickly by first unplugging the connector for your fuel pump. Refer to your service manual to locate the connector, as its location varies depending on your motorcycle. Typically, it is found underneath the seat, beneath the tank, or on the sides. Once the connector is unplugged, turn on the motorcycle and hold the start button for a few seconds. This action runs the remaining fuel in the system through to the engine, but since the pump is turned off, no new fuel enters the lines. This process effectively clears the system and relieves the pressure. Remember to remove the key and reconnect the fuel pump once you're done.
Additionally, for safety purposes, it is important to locate and disconnect the main fuse. The next step is to physically disconnect the fuel lines from the fuel pump. This process can vary depending on the style of the connector. Some connectors, such as the John Guest style, require two opposing buttons on the fitting to be pressed firmly to release the mechanism. This usually requires the use of both your thumb and forefinger, and it can take significant pressure to release. Other styles, such as the V7iii, have different mechanisms, so it's important to refer to your service manual for specific instructions.
Once the fuel lines are disconnected, you can proceed to clear them of any remaining fuel or sediment. This can be done by blowing outside air into the tank to displace the gas vapours. It doesn't take much heat for the fuel to vaporise, and you'll be able to tell when all the vapours are gone by sniffing the displaced air. Be careful not to inhale too much, as you don't want to inhale toxic fumes. Alternatively, you can use a shop vacuum (shop vac) to suck out the remaining fuel and sediment. Fill the tank and then empty it with the shop vacuum several times to ensure that all the sediment is removed.
Finally, it is important to note that some fuel may remain in the tank, especially if there is a collar around the inside of the top opening that prevents complete drainage. To remove the remaining fluid, you can use a manual drain pump or a siphon pump to extract it through the fill hole. You can also try absorbing it with a rag by holding the tank upside down and sticking the rag into the collar or lowering the rag into the tank while holding onto a corner.
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Remove the seat and any fairings
Removing the seat and fairings of a motorcycle is an important step in many maintenance tasks as it allows access to the bike's key components. The process can vary depending on the motorcycle make and model, so it is important to refer to the specific service manual for your motorcycle. Here is a general guide on how to remove the seat and fairings:
Remove the Seat:
- Secure your motorcycle on stable ground to ensure it doesn't tip over during the process.
- Refer to your motorcycle's service manual to understand the specific steps for removing the seat.
- Some motorcycles have a simple latch or button that needs to be released to pop the seat loose.
- Others may require the removal of screws or bolts using tools like Allen sockets or screwdrivers.
- For Indian Motorcycles, the process typically involves removing seat mount bolts and rear bracket bolts, then lifting and pulling the rear of the seat to disengage it from the frame mount.
Remove Fairings:
- Fairings are the body panels attached to or around the gas tank and can usually be popped off by hand or removed with tools.
- For R6 fairings, start by removing the hex bolts on each side of the bike, followed by the plastic rivets holding the fairings in place.
- Disconnect the indicators (turn signals) and remove the bolts holding the fairings to the bike.
- Some fairings may have additional components like inner panels, upper panels, or tail fairings that need to be removed separately.
- Remember to keep track of where each bolt and component goes during the removal process to facilitate reinstallation.
It is important to note that these steps may vary depending on the specific make and model of your motorcycle. Always refer to your motorcycle's service manual for detailed instructions specific to your bike.
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Disconnect tank straps and remove bolts
Disconnecting the tank straps and removing bolts from a motorcycle's gas tank is a necessary step for many repairs and maintenance tasks. Here is a detailed guide to help you through the process:
First and foremost, it is crucial to ensure your motorcycle is securely positioned. Use a kickstand on solid ground, a lift, or wheel stands to prevent the motorcycle from tipping over during the process.
Before disconnecting the tank straps and removing bolts, it is recommended to remove the fuel from the tank. This can be done by running it down or siphoning it out. Working with an empty tank is safer and more convenient.
Now, let's address the tank straps. Some motorcycles utilize tank straps for functional or aesthetic purposes. If your motorcycle has tank straps, it is necessary to disconnect them before proceeding. The process of disconnecting tank straps may vary depending on the motorcycle model, so refer to your service manual for specific instructions.
Moving on to the bolts, most motorcycle gas tanks have bolts at both the front and rear of the unit. To remove them, follow these steps:
- Remove any fairings or covers that may be obstructing access to the bolts. Fairings can usually be popped off by hand, but some may require the removal of bolts or screws.
- Locate the bolts holding the gas tank in place. Refer to your service manual if you are unsure about their location.
- Using the appropriate tools, loosen and remove the bolts. Again, the specific tools required may vary depending on the motorcycle model.
- Once the bolts are removed, leave the tank in place for now. You may need to access connections or hoses underneath the tank before completely removing it.
It is important to note that the above steps provide a general guide, and the specific process may vary depending on your motorcycle's make and model. Always refer to the service manual specific to your motorcycle for detailed instructions. Additionally, remember to work with caution and patience, as removing a motorcycle's gas tank can be a delicate task.
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Drain the gas from the tank
Before attempting to drain the gas from your motorcycle tank, it is important to secure your motorcycle. Ensure that it is in a stable and secure position. This could mean placing it on a kickstand on solid ground, lifting it, or putting it up on wheel stands.
Now, onto draining the gas. The first method involves siphoning. Siphoning is a common way to remove gas from a motorcycle tank. You can use a pump siphon, which can be purchased at Walmart or an auto-parts store, or a tube. If using a tube, place one end in the gas tank and the other end into a gas can or bucket. Then, use your mouth to suck on the tube to start the flow of gas. Be careful not to ingest any gasoline. Alternatively, you can blow air across the free end of the tube to start the suction. You can also cut the end of the tube at an angle and blow air across the opening, away from the hose, in the direction you want the gas to flow.
Another method of siphoning involves using a clear vinyl hose and a rag or washcloth. Cut a 5-foot section of hose and insert it into the tank as deep as you can. Place the other end of the hose into a gas can. Take the rag or washcloth and push it into the filler hole to create a seal around the hose. Now, blow into the short end of the hose to pressurize the tank and start a siphon.
If you don't want to use siphoning, you can try using a shop vac to suck the gas out of the tank. However, this method may not remove all the gas, and you may need to use a hand-operated siphon pump to get the rest out.
Additionally, you can try to run the gas out of the tank. First, disconnect the fuel pump by unplugging the connector, which may be located under the seat, tank, or on the sides. Then, turn on the motorcycle and hold the start button for a few seconds. This will run the remaining fuel in the system through to the engine without adding new fuel. Once done, remember to reconnect the fuel pump.
It is important to note that each motorcycle is unique, and you should refer to your specific service manual for additional instructions or variations.
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Frequently asked questions
The process of removing the fuel flap from a motorcycle gas tank varies depending on the motorcycle model. Here is a general guide:
- Secure your motorcycle on a kickstand, lift, or wheel stand to ensure it doesn't tip over.
- Remove the fuel by running it down or siphoning it out.
- Disconnect the fuel pump by unplugging the connector, which may be located under the seat, tank, or sides.
- Turn the motorcycle on and hold the start button to run the remaining fuel through to the engine.
- Disconnect the main fuse for safety.
- Remove the seat if necessary by pressing a button or unscrewing bolts.
- Disconnect any tank straps and remove tank bolts.
- Remove the gas tank and flush it out with water to remove any fuel traces.
You may need a variety of tools, including a service manual, hose, container, rag, screwdriver, forceps, and a saw.
First, locate and unplug the connector for the fuel pump. Then, turn on the motorcycle and hold the start button for a few seconds to run the remaining fuel to the engine. Finally, disconnect the main fuse for safety.
It is important to work in a well-ventilated area to avoid inhaling fumes. Ensure the motorcycle is secure and will not tip over. Also, disconnect the fuel pump and clear gas lines to relieve pressure before starting any work.
