Regan Brown
If you're looking to install a fuel tank stay on your TRX450R, there are a few steps you'll need to follow. While the process may seem daunting at first, with the right tools and guidance, you'll be able to get the job done safely and efficiently. The first step is to gather the necessary materials and tools, which may include items such as a new fuel tank, seals, and the appropriate tools for the installation process. The next steps will involve carefully removing the old fuel tank and preparing the new one for installation, ensuring a secure and proper fit.
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What You'll Learn
Remove the seat, front cowl and fenders
To remove the seat, front cowl and fenders of your Honda TRX 450R, follow these steps:
Firstly, to remove the seat, you have a few options. You could opt for a more comfortable, ready-made seat such as the hump seat, or a custom-made seat. For a custom-made seat, you will need to source the materials, foam and an industrial sewing machine to construct it. You could also consider modifying your current seat by adding more foam or a hump to improve comfort.
Next, to remove the front fenders, you can carefully drill out the rivets with a small drill bit. It is recommended to start with a pilot hole, then increase the size of the drill bit to avoid elongating the original hole. Alternatively, you can use side cutters to cut the back of the rivets, or a Dremel tool to grind off one side of the fender for a more precise cut. Ensure you completely remove the front plastics before beginning this process.
Finally, to remove the front cowl, you will need to carefully disassemble it from the bike. This may involve unscrewing or detaching any attached components, such as lights or indicators. Refer to the Honda TRX 450R manual or seek advice from a mechanic or online forums for specific instructions on removing the front cowl to avoid damage to your vehicle.
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Take out the bolts on the tank shrouds and tank frame
To take out the bolts on the tank shrouds and tank frame of a Honda TRX 450R, you will need to remove the two bolts on the tank shrouds and the two bolts holding the tank to the frame through the rubber grommets.
If the bolts are stuck, there are several methods you can try to remove them. One method is to use a power drill to spin the bolt and insert as you pry them up. Once they are loose, put them in a vice and remove the bolts. You can also try to turn the bolts by hand, using needle-nose vice grips to get a good grip on the bolt head.
If the bolts are broken, you may need to drill them out. You can use an impact drill to break the bolt loose. After removing the bolts, you can use epoxy to secure the brass insert back into the tank.
Alternatively, you can cut a slit in the plastic around the bolt head to create a quick-release mechanism, rather than removing the bolt entirely.
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Close the petcock valve
Closing the petcock valve on a Honda TRX 450R is important when removing the fuel tank to prevent fuel from spilling onto the motor.
To close the petcock valve, first locate the valve on the fuel tank. It is usually found at the bottom of the tank, connected to a fuel line. Make sure that the valve is in the "off" position by turning it clockwise until it is fully closed. You may need to use a pair of needle-nose pliers to get a better grip and apply more force.
It is important to ensure that the petcock valve is properly aligned and sealed. Some users have reported issues with the petcock valve not shutting off completely, even when lined up correctly. This may be due to a faulty gasket or a manufacturing defect. If the valve does not seal properly, fuel may leak out, even when the valve is closed.
If you are experiencing issues with the petcock valve not shutting off properly, there are a few potential solutions. One option is to purchase an aftermarket petcock valve, which may offer improved performance and better fuel flow. Make sure to choose a compatible brand and model, as there may not be a universal option. Another option is to replace the entire fuel tank, as the threads that the bolts screw into may be damaged, causing the valve to not seal properly.
In some cases, you may need to get creative to remove a stubborn bolt or valve. One suggestion is to use a drill to spin the plastic until it melts and then epoxy the insert. Alternatively, you can grind the heads off the bolts and use epoxy to secure the nuts before installing a new petcock.
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Remove the hose with a pair of pliers
To remove the hose with a pair of pliers, first, ensure you have the right type of pliers for the job. Hose removal pliers are ideal, as they are designed to apply even pressure around the hose to push it off without causing damage. Some pliers have rubberized grips for a comfortable and secure grip. You can also use needle-nose pliers, but be aware that using the wrong tool can stretch or tear the hose, causing leaks.
Once you have the correct pliers, locate the hose you need to remove. In the case of the Honda TRX 450R, you will need to remove the fuel hose. To do this, pinch the band holding the hose to the 90-degree bend leading to the fuel line with your pliers. This will allow you to remove the hose without spilling any fuel.
If the hose has been in place for a long time, it may be more difficult to remove due to heat and clamping pressure. In this case, hose removal pliers are especially useful as they can provide the necessary force without damaging the hose. Grip the hose firmly with the pliers and apply even pressure to push or pull it off the barb or fitting.
It is important to be careful when removing hoses to avoid spills or leaks. Make sure the petcock valve is in the off position before removing any hoses connected to the fuel system. This will prevent fuel from spilling onto the engine or other components. Always refer to the service manual or seek professional help if you are unsure about any steps in the process.
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Pull the tank free
To pull the tank free, you must first remove the two bolts on the tank shrouds. Then, remove the two bolts holding the tank to the frame through the rubber grommets. Next, take off the seat and remove the strap across the bottom of the tank. Make sure that your petcock valve is in the off position to avoid spilling fuel on your motor. With a pair of needle-nose pliers, pinch the band holding the hose to the 90-degree bend leading to the fuel line. It will spill a little gas in the line above where you disconnected it. Now, pull your tank free and clear from the machine.
You can then pour out the remaining gas from the filler spout. After that, open up the petcock and rock the tank around to get rid of any remaining gas.
Alternatively, you can pull the fuel line off the carb and put your tank on reserve. Or, you can pull the tank completely off by removing the seat, front cowl, and front fenders.
It is important to note that this process may vary slightly depending on the make and model of your vehicle, and it is always recommended to refer to the manufacturer's instructions or seek professional assistance if you are unsure.
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