REMOVING THE GAS TANK
You don't have to pull the tank to pull the plugs. However, if you ever want to pull the tank, it's very simple and straight-forward.
You should wait until it is nearly empty, though. Either that or siphon out all the gas.
1) Remove the rider's seat.
2) Remove the two bolts holding the rear of the tank.
3) Remove the small black connector on the right side of the tank.
4) Lift the rear and prop it up. A can of Pork and Beans works well.
5) Reach in on the left side near the front of the tank and turn off the gas valve (horizontal is off, vertical is on).
6) Remove the funny clamp on one of the fuel hoses and discard it.
7) Squeeze the wire clamp on the other hose and slide it down a few inches.
8) Remove the two hoses and secure them pointing up.
9) Remove the two small rubber hoses at the front left of the tank.
10) Lift, pull back slightly, and carefully remove the tank.
Note, that if there is very much gas still in the tank, it will run out of the hose going to the sub tank when you remove that hose from the tank.
It would be a good idea to have something you could plug the hose with. I have used an old 7/16” or ½” bolt stuck into the end of the hose.
Also, if there is still gas in the tank it will run out one of the small nipples on the front if the tank is tilted in that direction.
That funky clamp that is on one of the rubber hoses can be reused but it’s a better idea to replace it with one of the screw-tight hose clamps.
These are available at most hardware stores and home centers like Lowe’s and Home Depot.
Replacing the tank just goes in the opposite sequence.
The most difficult part is connecting those two smal hoses at the front of the tank.
If you remove that fake air filter chrome cover on the left and front frame cover it will give you more finger room.
The shorter hose goes to the front connection. The longer hose to the rear connection.
1) Lift, push forward slightly, and carefully replace the tank.
2) Lift the rear and prop it up. Use the Pork and Beans.
3) Replace the two small rubber hoses at the front left of the tank.
4) Install the new clamp on the hose that had the funky clamp.
5) Replace the two hoses and tighten the new clamp.
6) Squeeze the wire clamp on the other hose and slide it up.
7) Reach in on the left side near the front of the tank and turn on the gas valve (horizontal is off, vertical is on).
8) Replace the small black connector on the right side of the tank.
9) Replace the two bolts holding the rear of the tank.
10) Replace the rider's seat.
11) Don’t forget to get the key for the ignition.
12) Heat the Pork and Beans and eat them – you’re now hungry!
TWO NOTES OF CAUTION WHEN REPLACING THE GAS TANK:
CAUTION #1: Be 100% certain not to pinch 'even slightly' the vent hoses coming from the tank, otherwise engine will run erratically, at best.
CAUTION #2: Be 100% certain the tank's petcock is turned on, otherwise you won't ride far before your engine shuts down and begins to laugh at your mistake.
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