How to remove and install fuel tank

First, remove the fuel tank cover.

For details, see the maintenance record “How to remove fuel tank cover”.

あわせて読みたい

How to remove fuel tank cover After some work, I repeated the removal and installation of the fuel tank cover, and I will summarize how I did it and what I noticed. Actually, it was more …

＜Condition of fuel tank cover removed＞

From this state, the work begins.

First, remove the fuel hose.

＜Remove fuel hose connector cover＞

Remove the fuel hose connector cover that holds the fuel hose connector.

1. Press down on the claw parts and
2. Lift it up

＜Remove fuel hose connector 1＞

With fuel hose connector pliers,

1. Press down on the two claws of the fuel hose connector.
2. Lift it up slightly.

These pliers are used to remove the connector with the button, and I happened to be able to use them this time.
If you can use your fingers to remove the connector, that is the best way.

＜Remove fuel hose connector 2＞

Now, lift up the connector.
It is a little stiff because of the tightness of the O-ring.

When I removed the connector, there was no splashing of fuel.
The ignition switch had not been turned on the previous day (the fuel pump was not energized), so the fuel pressure may have been low.

Note that if you can prepare a platform on the right side of the vehicle body that is about the same height as the fuel tank, there is no need to disconnect the fuel hose.

＜Remove fuel hose＞

From the right side of the fuel tank, remove the fuel hose grommet.

＜Remove fuel pump connector＞

Left: Disconnect fuel gauge connector
Right: Disconnect fuel pump connector

1. Push the lever to unlock and pull the connector to disconnect.
2. Pull the connector to remove it.

＜Remove fuel overflow hose＞

Disconnect the fuel overflow hose from the left side of the fuel tank.

1. Using pliers or the like, push down the clip.
2. Using a hose puller pliers, remove the hose from the fuel tank.

＜Remove overflow hose and wiring＞

From fuel tank,

1. Remove fuel overflow hose grommet
2. Remove the fuel gauge and fuel pump wiring

The grommet of the genuine part did not fit into the groove of the fuel tank. So, it was replaced with a commercially available grommet.

For details, please refer to the maintenance record “Replace grommet and cap around fuel tank”.

あわせて読みたい

Replace grommet and cap around fuel tank ＜Fuel tank cover＞ When I removed the fuel tank cover previously, I noticed the following two things. The drain hose grommet leading to the petrol filling p…

＜Disconnect buzzer wiring for burglar alarm＞

I have a theft alarm buzzer on top of the fuel tank. So, I will also disconnect that wire.

Next, begin removing the fuel tank itself.
The fuel tank is held in place by a shaft at the front and two bolts at the rear.

＜Remove washer＞

Remove the washer on the forward shaft.

＜Remove shaft 1＞

Remove the shaft with a T-handle with a socket (13 mm) attached.

Since the tip of the shaft hits the inside of the socket, a slightly deeper socket is better.

＜Remove shaft 2＞

When lifting the shaft, do not forget to remove the washer attached under it.

＜Remove bolts＞

Using a T-handle with a hexagon socket (5 mm), remove the rear two bolts.

＜Remove bracket＞

Lift up the bracket so as not to drop the bolt, washer, and collar.

The collar may remain in the grommet. So, be careful not to lose it.

＜Remove fuel tank＞

Now, lift up the fuel tank and remove it.

It is lighter to work with less fuel.

＜From the front＞

With a plastic tank, rust does not occur and it is less careless to handle than a steel tank.
When I read “no rust in the tank” in the description of an R125 being sold at an auction, I sometimes think that there is indeed no rust.

＜From the back＞

I did not check whether it is because of the shape or the center of gravity, but it leans to the left side.
Is it possible that the center of gravity is intentionally placed on the left side where the sidestand is located?

＜Condition of fuel tank removed＞

In this condition, the air cleaner box and throttle body can be easily serviced.

Now, let’s start the installation.

＜Install collars＞

Place the fuel tank on the frame and place the collars beforehand in the grommet at the rear.
On my moto, the collars were attached closer to the front.

Then, temporarily tighten the forward washer and shaft.
(See STEP 13 for details.)

＜Tighten bracket＞

After temporarily tightening the rear bracket, tighten two bolts using a torque wrench with a hexagon socket (5 mm). (10 Nm)

＜Tighten shaft＞

Tighten the forward shaft with a torque wrench attached to the socket (13 mm). (10 Nm)

＜Install hose and other＞

Left side:

1. Install the fuel overflow hose to the tank.
2. Install the fuel gauge and fuel pump wiring to the tank.

Right side:

3. Install the fuel hose to the tank and insert the fuel hose connector.

Middle:

4. Connect the burglar alarm buzzer wiring to the tank.

＜Install fuel hose connector cover＞

Finally, insert the fuel hose connector cover into the fuel hose connector.

Oh, my finger is in the picture.

Then, just install the fuel tank cover and you are done.

For details, please refer to the maintenance record “How to install fuel tank cover”.

あわせて読みたい

How to install fuel tank cover Install the cover that was removed in the maintenance record ‘How to remove fuel tank cover’. When removing and installing the cover, it catches on the fuel …