Removal and Replacement

Fuel Tank Location:

WARNING: Observe fire safety precautions.

1. Disconnect the NEG. battery cable and insulate.
2. Remove the fuel filler cap and draw out all fuel.

NOTE: The fuel tank capacity is approx. 19 gals. (72 liters)

Fuel Tank View:

3. Remove the sealing sleeve (60a).
4. Remove the back rest for the 3rd. seat or the package compartment partition.
5. Fold the front storage compartment covering forward.
6. Remove the breather line (64a).
7. Remove the fuel gauge sending unit electrical connector.
8. Remove the fuel supply hose (69), return hose (70) and the leak-off line (72).
9. Remove the breather valve (51).
10. Disconnect the exhaust system to allow for fuel tank removal.
11. Remove the splashguard (58) for the filler neck.
12. Remove the U-rail (56). Support the fuel tank as necessary.
13. Remove the fuel tank front mounting hardware.
14. Push the exhaust system to the left and remove the fuel tank. Be sure that breather line on the filler neck does not get entangled with cables or other components.
15. Remove the fuel filter (68) and clean or replace as necessary.
16. Reinstall the fuel tank in reverse manner.

NOTE: a. Renew seal (68a).
b. Torque the fasteners (50c) to approx. 15.5 ft. lbs. (21 Nm). Make sure washers (50b) are in place.
c. Torque the fuel strainer (68) to approx. 28.5 ft. lbs. (39 Nm).
d. Torque the fuel gauge sending unit to approx. 28.5 ft. lbs. (39 Nm).

17. Run the engine and check for fuel leaks.