Regan Brown
Removing the fuel tank from a Yamaha motorcycle can be a challenging task, as demonstrated by the variety of methods and tools that owners of the Yamaha V-Star and Star Stryker have used. Before removing the tank, it is important to ensure that the tank is empty. Some owners have recommended using a manual pump to drain the tank, while others have suggested turning the petcock valve to shut off the fuel line. Once the tank is empty, the next steps involve removing bolts, disconnecting hoses, and unplugging electrical connectors. Some owners have also recommended removing additional parts, such as the rear fender, shocks, and mudguard, to make the process easier. It is important to note that some owners have encountered issues with rust and clogged petcocks, which may require additional steps for removal. Overall, while the process of removing the fuel tank from a Yamaha motorcycle can be complex, online forums provide a wealth of advice and experiences to guide owners through the process.
How to remove the fuel tank from a Yamaha motorcycle
| Characteristics | Values |
|---|---|
| Motorcycle models | Yamaha Star Stryker, Yamaha Star Cycle V-Max VMAX, Yamaha VStar 1100 |
| Tools required | Socket wrench, 12mm socket, pliers, metal snips, manual pump, aftermarket manual, socket set, lubricant, WD40, rust remover, new gas cap, rag, fuel line, bucket, rubber mallet, penetrant, larger pair of pliers |
| Steps to remove the fuel tank | 1. Ensure the gas tank is empty. 2. Remove bolts and disconnect hoses and connectors. 3. Slide the tank out towards the rear of the bike. 4. Remove the rubber grommet. 5. Remove the locking tank cap. 6. Disconnect the fuel level gauge electrical plug. 7. Pull the tank straight out on the LHS of the bike. |
| Notes | Some users report difficulty in figuring out the "trick" to the tank manipulation. |
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What You'll Learn
Drain the fuel tank
To drain the fuel tank of a Yamaha V-Star, you will need to first drain the fuel. This can be done by using a manual pump to siphon the fuel out of the tank. You can purchase a manual pump from your local auto store for under $10.
Alternatively, you can remove the petcock and drain the remaining gas. You can then invert the tank and douse the insides with PB/WD to soak. This will help to loosen any rusted components. If your gas cap is jammed due to rust, you can try soaking it with WD40 and/or rust remover. Insert the key into the lock halfway and use it to drop the WD40 inside. Spray WD40 beneath the cap to help rehydrate the rubber seal and let it soak for 24 hours. If it still doesn't work, repeat the process and then leave the bike under sunlight for an hour before attempting to open the gas cap.
Once the fuel has been drained, you can proceed to remove the fuel tank. This will involve removing bolts and disconnecting hoses and connectors. Make sure to have a rag handy to catch any fuel that may spill during the process.
- Remove the rubber grommet below the assembly, which is between the assembly and the frame tank mounting plate.
- Remove the locking tank cap.
- Disconnect the fuel level gauge electrical plug from the harness next to the rear brake master cylinder.
- Slide the tank towards the rear of the bike to disengage the tank support tang from the rubber bush.
- Pull the tank straight out on the left-hand side of the bike.
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Remove bolts, hoses and connectors
To remove the bolts, hoses, and connectors, start by making sure your gas tank is empty. You can drain the fuel using a manual pump or by turning the petcock valve off and placing a bucket underneath. Once the tank is empty, you can start disconnecting the hoses and removing the bolts.
On the left side of the tank, use a pair of pliers to remove the clamp and disconnect the hose. There should be two bolts, one on each side of the tank, that need to be removed. Slide the gas tank back towards the tail to unhook it from the front slots. When the tank is lifted about 4 inches, you can unplug the electrical connector and disconnect the remaining hoses.
Be careful when handling the fuel and hoses, and have a rag handy to catch any spills or drips. It may be helpful to take pictures or make notes on how the hoses and connectors are attached to ensure proper reassembly.
Some Yamaha models may have additional connectors and hoses that need to be removed. For example, the Yamaha Star Cycle V-Max VMAX has a connector under the seat that goes to the low fuel light. It also has a fuel level gauge electrical plug that needs to be disconnected.
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Use tools like pliers, metal snips, and socket wrenches
To remove the fuel tank from a Yamaha Star Stryker, you will need to use a combination of tools, including pliers, metal snips, and socket wrenches. Here is a detailed guide on how to use these tools to remove the fuel tank:
First, ensure that your Yamaha's gas tank is empty. This step is crucial as working with a full or partially full tank can be dangerous and messy.
Now, let's begin with the tools. For this process, you will need a 12mm socket wrench, a standard set of pliers, and metal snips. Start by locating the hose on the left side of the gas tank. Using your pliers, carefully remove the clamp that secures the hose in place. This step may require some force, so be sure to use the pliers for a secure grip. Once the clamp is off, set it aside and move on to the next step.
With the clamp removed, you can now access the bolts that secure the gas tank in place. Using your 12mm socket wrench, remove the two bolts, one on each side of the gas tank. Place these bolts somewhere safe, as you will need them later when reassembling the bike.
At this point, you should be able to slide the gas tank towards the tail of the bike. This action will unhook the tank from the front slots. Lift the tank gently, and once it is lifted about 4 inches, you can access the electrical connector. Using your pliers or wrench, carefully unplug the electrical connector. Be gentle with this step, as you do not want to damage any wires or connectors.
Now, you will need the metal snips. If you encounter any hoses or clamps that are difficult to remove, use the metal snips to carefully cut through them. This step should be done with caution, as you do not want to damage any surrounding components.
Finally, with the bolts, clamp, and connectors removed, you can carefully lift and remove the gas tank from your Yamaha. Place it in a safe location, and remember to handle it with care, as it may still contain residual fuel.
This process requires attention to detail and a careful approach to ensure the safety of your bike and yourself. Take your time, and ensure that all tools and connections are handled securely.
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Remove the rear fender and mudguard
To remove the rear fender and mudguard of a Yamaha V-Max, follow these steps:
First, remove the rubber grommet between the assembly and the frame tank mounting plate. Then, remove the two bolts holding the rear fender to the frame. With the bolts removed, carefully sit the fender on the rear tire, ensuring that you do not disconnect any wiring from the fender's tail light loom. Next, remove the mudguard from the fuel tank. There should be one Phillips-head bolt attaching the mudguard to the fuel tank, facing the tire. Once the bolt is removed, carefully lift and separate the mudguard from the fuel tank.
It may be helpful to also remove the rear shocks from the top mounts, allowing the rear wheel to drop and making it easier to access the fender bolts and mudguard without having to remove the rear wheel entirely. Additionally, consider removing the rubber insulator on the other side of the tank to provide more room to maneuver during the process.
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Disconnect the fuel lines
Disconnecting the fuel lines is a crucial step in removing the fuel tank from a Yamaha motorcycle. While the specific steps may vary slightly between different Yamaha models, here is a detailed guide on how to disconnect the fuel lines when removing the fuel tank from a Yamaha V-Star.
First and foremost, it is essential to ensure your safety. Before beginning any work on your Yamaha V-Star, make sure the engine is turned off and the bike is parked on a level surface. Wear protective gear, such as gloves and eye protection, to safeguard against any potential hazards.
Now, let's begin with the fuel lines. The Yamaha V-Star fuel system involves multiple connections, including hoses, clamps, and electrical connectors. Here is a step-by-step guide to disconnecting the fuel lines:
- Start by locating the fuel lines. On the Yamaha V-Star, the fuel lines are typically accessible from the left side of the motorcycle.
- Identify the hose clamp that secures the fuel line to the fuel tank. This clamp needs to be loosened or removed to detach the hose.
- Using a suitable tool, such as a pair of pliers, carefully loosen or remove the hose clamp. Be gentle to avoid damaging the clamp or the surrounding components.
- Once the hose clamp is loosened or removed, carefully disconnect the fuel hose from the fuel tank. You may need to wiggle the hose gently to detach it completely.
- After disconnecting the hose, there may still be residual fuel in the line. Have a rag or container ready to catch any fuel that might spill or drip from the line.
- Some Yamaha V-Star models may have additional fuel connections or components, such as a fuel shut-off valve or a petcock valve. Make sure to identify and address these components as well. Refer to your Yamaha V-Star's service manual or seek guidance from a Yamaha dealer if you're unsure about specific components.
- If your Yamaha V-Star has a fuel shut-off valve, remember to close it before proceeding further. This will prevent any further fuel flow and minimize the risk of leaks during the tank removal process.
- In some cases, you may need to remove or adjust additional components to gain better access to the fuel lines and the fuel tank. This could include removing the rear fender, the rear left shock, or any other parts that might obstruct your access.
- Once the fuel lines are disconnected, carefully set them aside, ensuring they don't interfere with other components or create a trip hazard.
- Before proceeding with the fuel tank removal, inspect the disconnected fuel lines for any signs of damage, leaks, or deterioration. If any issues are identified, address them appropriately, such as replacing damaged hoses or clamps.
Remember, always refer to your Yamaha V-Star's service manual for model-specific instructions and safety precautions. If you're uncomfortable or unfamiliar with any aspects of fuel tank removal, don't hesitate to seek assistance from a qualified motorcycle mechanic.
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Frequently asked questions
First, make sure your gas tank is empty. Then, follow these steps:
- Remove the rear brake caliper and caliper support arm, rear axel and tire, rear tire/tank mud guard, left passenger foot peg, breather tubes, rubber filler overflow, main fuel line to the filter, filter and upper rubber filter holder, bottom drain hex bolt, and unplug the sender unit wires.
- Unscrew the two upper tank main fasteners, large rubber tang, and small rubber side tangs.
- Remove the gas cap.
- Slide the tank towards the rear of the bike to disengage the tank support tang from the rubber bush.
- Pull the tank out from the left-hand side of the bike.
You will need a socket wrench, a 12mm socket, and pliers.
Try soaking the gas cap with WD40 and/or rust remover. Insert your key into the lock and use it to drop the WD40 inside. Spray WD40 beneath the cap and let it soak for 24 hours. If this doesn't work, repeat the process and then leave the bike under sunlight for an hour before attempting to open the gas cap.
