December 2nd, 2008, 11:59 PM | #1 |
Join Date: Nov 2008 Posts: Too much.
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DIY- How to Remove the Gas Tank
I thought it might come in handy for anyone looking to remove the tank...
First, take off both the side covers and lower fairings using this DIY- http://www.ninjette.org/forums/showthread.php?t=9933 This is for a 49 state bike. If you have a cali model there may be more steps/hoses than this to remove the tank. 1. Take seat off. One Allen on each side of the seat. There is a washer inside each mounting hole of the seat. Don't lose them. -015.jpg 2. remove 2 10mm bolts at the rear of the tank along with the bracket they hold down. 5.jpg 3. prop up the rear of the tank with a small piece of 2x4 so you can gain access under the tank. -016.jpg 4. unplug the gray vent hose from front left side of the tank. 1.jpg 5. under the tank, undo the fuel sender connector. 2.jpg 6. under the tank, remove a vacuum hose that runs to the back of the fuel petcock. 3.jpg 7. under the tank, make sure the fuel tap is in the "on" position and remove the fuel hose from the fuel petcock. The valve is vacuum operated and with no vacuum, no fuel will pour out of the tank as long as it is in the "on" position. Do not leave it in the prime position as fuel will run out... ask me how I know. 4.jpg At this point you should be able to lift the tank off by pulling the rear of the tank up and towards the rear of the bike. Make sure the black console plastic that wraps around the upper tank fairing mounting holes are free. When you put the tank down, make sure you place it on a blanket or cloth to avoid scratching it and don't let it rest on the petcock. I use a small 2x4 under that area ahead of the petcock to make sure the tank isn't resting on it. -016.jpg No need to drain the tank before removal, but if you do start with a full tank, it is quite heavy compared to it empty. Again, ask me how I know. |
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January 24th, 2009, 06:11 AM | #2 |
ninjette.org guru
Name: Tom
Location: Dayton, OH
Join Date: Jan 2009 Motorcycle(s): '13 Ninja 300 '09 Boulevard C50. '08 250r(TOTALED BY DEER) Posts: 467
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I am plugging all the lines(bike and tank, and I still get tons of fumes if I leave it more than 12 hrs. Any suggestions?
**EDIT** With my fuel tap "on" i still got steady leaking (apparently my cap on the large tap line was 1 size too big and let some fuel out) Hopefully with the correct(more snug cap) I will be safe **EDIT**
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CHEERS!!! Last futzed with by Tigerpaw; January 24th, 2009 at 07:50 AM. |
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January 24th, 2009, 10:57 AM | #3 |
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with the 2 lines (fuel and vacuum) removed from the fuel tap, there should not be any fuel leaking if you have the tap on the "on" position. Fuel will leak if you have it in the "prime" position. If it is in the prime position, switch it to on and it should stop leaking. If not, you have a defective fuel tap.
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January 24th, 2009, 12:56 PM | #4 |
ninjette.org guru
Name: Tom
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Defective, you think?
I just thought it had something to do with pressures in the tank...since I have not started fore some time there would beno pressure I will also try cycleing the valve later(doubt that's it) Just spitballing before I buy a new tap(expensive i'm sure)
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January 24th, 2009, 01:38 PM | #5 |
ninjette.org member
Name: John
Location: CA bay area
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Thanks for the write up! it really helped me take my tank off the cali model bikes have a total of three more hoses to take off. theirs an additional two more hoses on the left side of the tank, and one hose underneath that connects to the fuel sender.
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January 24th, 2009, 02:30 PM | #6 |
ninjette.org sage
Name: David
Location: Wellington, New Zealand
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Tom, what order did you disconnect the pipes into the fuel petcock? I know that you will get a small amount of fuel come out if it is the large one before the small. But if you disconnect the small pipe first (the vacume) then the only fuel that will leak out is what is currently in the fule hose. Unless you have got a deffective fuel petcock.
The presure in the tank its self will not matter as it is the vacume line that provides the ability to flow (unless fuel petcock is deffective). You can always open the tank lid to release the pressure in the tank. |
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January 24th, 2009, 02:51 PM | #7 | |
ninjette.org guru
Name: Tom
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Quote:
((Too cold in the garage right now to tinker with it))
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January 24th, 2009, 02:59 PM | #8 |
ninjette.org sage
Name: David
Location: Wellington, New Zealand
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Hmm, sounds like you could have a deffective fuel petcock there.
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January 24th, 2009, 04:48 PM | #9 |
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are you taking the fuel line off at the carb or at the fuel petcock?
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January 24th, 2009, 05:19 PM | #10 |
ninjette.org guru
Name: Tom
Location: Dayton, OH
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pulling off at petcock and capping
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January 24th, 2009, 05:23 PM | #11 |
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Sounds like a defective petcock. There is a vacuum operated diaphragm inside the petcock that allows fuel to flow once it receives vacuum from the carbs.
On mine, I pull the fuel and vacuum lines off at the petcock and remove the tank an lay it down on a blanket. I have never had any gas leak from the petcock once the tank was removed from the bike. |
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March 13th, 2009, 06:24 PM | #12 |
ninjette.org member
Name: Angelo
Location: North New Jersey
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does the tank have to be empty?
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March 13th, 2009, 07:19 PM | #13 |
ninjette.org sage
Name: David
Location: Wellington, New Zealand
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Please read the original post again... Kelly states the answer in his DIY.
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March 14th, 2009, 06:16 AM | #14 |
ninjette.org member
Name: Angelo
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yea i know but i still dont think that no fuel will poor out... ehh idk... i wouldnt trust that vaccum ..
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March 14th, 2009, 07:12 AM | #15 |
The Sexy Filipino
Name: Jordan
Location: Bakersfield, Ca
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Why? We are telling you it doesn't.
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March 14th, 2009, 09:38 AM | #16 | |
Ramen Rider
Name: Gary
Location: Honolulu, Hawaii
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Quote:
if you are scared, then run the tank until it is almost empty first. the first time i did it, i was kind of nervous it may leak too. so i can understand your skepticism. |
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March 14th, 2009, 09:46 AM | #17 |
ninjette.org certified postwhore
Name: Kim
Location: mundo de ensueño
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well, if you know so much more than the rest of us, why the hell are you asking? just be sure not to swallow any while you are sucking it out with the straw
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March 14th, 2009, 12:26 PM | #18 |
ninjette.org member
Name: Angelo
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March 14th, 2009, 12:46 PM | #19 | |
ninjette.org sage
Name: David
Location: Wellington, New Zealand
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Quote:
Listen to those of us who have had the fuel tank off many times. I have even taken it off right after I filled up. Stupid idea , but still able to be done without any leaking.
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2008 GREEN Kawasaki Ninja 250R. AreaP Quiet Core Carbon Fibre : 8000k HIDs : Dynojet Jet kit : Double Bubble Windscreen |
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March 14th, 2009, 01:54 PM | #20 |
ninjette.org certified postwhore
Name: Kim
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March 14th, 2009, 01:55 PM | #21 |
ninjette.org sage
Name: David
Location: Wellington, New Zealand
Join Date: Dec 2008 Motorcycle(s): 08 Ninja 250R in Green! (Sold) Now 2011 Triumph Daytona 675 SE Posts: 564
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__________________________________________________
2008 GREEN Kawasaki Ninja 250R. AreaP Quiet Core Carbon Fibre : 8000k HIDs : Dynojet Jet kit : Double Bubble Windscreen |
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March 14th, 2009, 08:37 PM | #22 |
ninjette.org member
Name: Angelo
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hey, no need to be an internet tuff guy callin names n stuff...and i am taking your advice, its just called being a little skeptical because my tank is full ( storage), plus i never done this before, so being skeptical is OK... dont have to jump on my case... i take kkims advice on many things now, trust completely...being skepticle doesnt mean not listening to it.
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March 20th, 2009, 09:47 AM | #23 |
ninjette.org sage
Name: patricK
Location: San Jose, CA--BAY AREA!
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Thanks for showing the difference on the CA version. You don't happen to have more pictures of this do you?
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March 20th, 2009, 05:44 PM | #24 |
Wannabe Reborn
Name: Unregistered
Location: Cincy Ohio
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I took my tank off for the first time. I read this DIY previously and after eyeballing the tank area, felt pretty confident. I didn't pay particular attention to the big hose/small hose item at first. When I removed the tank, the fuel line leading to the carbs, I had fuel leak out of there. Put the lines back on petcock, removed the small hose then big hose and after I set the tank down with a 2x4 under it, fuel still leaked out. I tried cycling the valve to PRI then back to ON, and it still had a slow drip! I've never had any fuel issues, got great mileage(58mpg) and can't understand how after 3500 miles I have a faulty petcock...? After so many people have said they have drips, is it slightly possible that this is somewhat normal?
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March 20th, 2009, 05:49 PM | #25 |
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It should not drip when in the "on" position. You could very well have a faulty petcock.
It wouldn't affect fuel mileage as there are little valves that regulate when to fill up the carbs in the carbs themselves. I've never had problems with fuel leaking out (even slowly) when i have removed the tank. |
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March 21st, 2009, 04:32 PM | #26 |
ninjette.org sage
Name: patricK
Location: San Jose, CA--BAY AREA!
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What's the easiest and best way to remove these hoses? I can take clamp off no problem. The hoses are connected pretty tightly and snug. I tried to use a type of clamp to grab and try and twist them off but it tore the hose a little bit at the base. I'm scared to proceed any further until I find a better way. Please help
BTW I have CA version w/ the extra hoses. While I was removing the one with the red dot, the first one I tried to undo, some gasoline came out, and so I stopped. Know anything about this?? I do have the fuel tap in the "ON" position so I didn't understand why this happened. Last futzed with by paterick4o8; March 21st, 2009 at 04:39 PM. Reason: clarification |
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March 21st, 2009, 04:41 PM | #27 | |
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Quote:
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March 21st, 2009, 04:51 PM | #28 |
ninjette.org sage
Name: patricK
Location: San Jose, CA--BAY AREA!
Join Date: Mar 2009 Motorcycle(s): '08 blue 250R [sold]. '09 lime ZX-6R [stolen :( ]. '06 blue 636. Posts: 918
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Thanks for the quick reply Kelly. I may have to try the WD-40 method as this hose won't easily slide off no matter how hard I tried. Off to the hardware store I go.
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March 21st, 2009, 05:31 PM | #29 |
Join Date: Nov 2008 Posts: Too much.
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as a note, it doesn't need to be wd-40... any type of spray lubricant should work.... silicone spray, lithium grease, armorall, even water, maybe. The thing is to work it down between the hose and spigot.
sorry, should have mentioned that in my first post. My assumption was that everybody has a wd-40 type lubricant lying around. |
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March 21st, 2009, 05:40 PM | #30 |
ninjette.org sage
Name: patricK
Location: San Jose, CA--BAY AREA!
Join Date: Mar 2009 Motorcycle(s): '08 blue 250R [sold]. '09 lime ZX-6R [stolen :( ]. '06 blue 636. Posts: 918
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haha yeah I figured that. I had some but I can't find it anywhere + I need to fix a squeak on a door anyway and I always so 2 birds in one stone
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March 25th, 2009, 04:34 PM | #31 |
250Arrrgh!
Name: Andrew
Location: San Francisco
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Let me just follow up on what John noticed about the very special CA models. Notice the 3 hoses on the side of the tank. Left one is for air, middle one is for orange juice (with pulp), and right one is for introducing gasoline to the OJ mixture. That big black box with the thick rubber straps around it is where you insert whole oranges.
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March 25th, 2009, 05:06 PM | #32 |
Join Date: Nov 2008 Posts: Too much.
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drawing to go with your pic. from a pregen, but essentially explains what those hoses are for.
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August 24th, 2009, 07:09 PM | #33 |
ninjette.org member
Name: James
Location: GE
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Pulled my tank 3/4 full - no leaks. Also remember to disco the wire for the fuel guage. Its on the rt side.
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December 4th, 2009, 01:51 PM | #34 |
Master of Nothing
Name: Blue
Location: Hilo, Hawaii
Join Date: Oct 2009 Motorcycle(s): Yamaha YZF600R, Kawasaki Ninja 250R, Honda CRF450X, CRF230F, CRF100F, CRF70F Posts: 11
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On my girlfriends bike, gas POURS out of the petcock when you remove the vacuum hose first and then the fuel line hose second. Highly doubtful it is a "faulty" petcock with only 700 miles on the clock. This brings up an issue with me of "factory defects" or "faulty/inferior" parts used for a "budget" bike. This would then bring up further concerns across the whole board on the quality of the bike itself. What's next? Faulty master cylinders on the breaks? That would be "bad"!
I also have questions about the step by step illustrations at the top of this thread posted by kkim. (not knocking you, Kelly, since you are obviously one of the "Ninjette Gawds" here, but please clarify for the newbies) Step 6, Kelly says: "under the tank, remove a vacuum hose that runs to the back of the fuel petcock." Step 7, "under the tank, make sure the fuel tap is in the "on" position and remove the fuel hose from the fuel petcock. The valve is vacuum operated and with no vacuum, no fuel will pour out of the tank as long as it is in the "on" position. Do not leave it in the prime position as fuel will run out... ask me how I know." The photo that depicts the order of events given in steps 6 & 7, clearly show the fuel line disconnected and the vacuum hose still attached. So... which is it? Last futzed with by Blue Hawaii; December 4th, 2009 at 04:01 PM. |
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December 4th, 2009, 01:57 PM | #35 |
Join Date: Nov 2008 Posts: Too much.
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if you have the petcock set to "on" instead of "pri", it does sound like something might be up w/ the diaphragm in the petcock.
can't say for sure if I've ever removed the fuel line first, then the vacuum line, though, but I can say I've never had a problem with fuel leaking out the petcock once removed other than a few drops. |
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December 4th, 2009, 02:48 PM | #36 |
ninjette.org certified postwhore
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December 4th, 2009, 02:58 PM | #37 |
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it's either/or. It really shouldn't make any difference what gets disconnected first. With the engine not running, you no longer have a vacuum source to the petcock diaphragm, so the petcock should theoretically be in the "off" position. (unable to flow fuel through it) That's the job of that diaphragm... to stop fuel flow.
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December 4th, 2009, 08:42 PM | #38 |
self wrencher
Name: john
Location: houston
Join Date: Dec 2008 Motorcycle(s): 08 250r and 07 600r Posts: A lot.
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remember,
no primo = no problemo |
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December 5th, 2009, 05:12 PM | #39 |
Master of Nothing
Name: Blue
Location: Hilo, Hawaii
Join Date: Oct 2009 Motorcycle(s): Yamaha YZF600R, Kawasaki Ninja 250R, Honda CRF450X, CRF230F, CRF100F, CRF70F Posts: 11
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I refused to believe that my girlfriends petcock (no pun intended) is "faulty", so this afternoon, I removed it from the tank and pried the diaphragm valve apart (very gently) to see what was up inside. It looked as only a good cleaning was in order, so I used some quality carb cleaner and put it all back together. Guess what?
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December 5th, 2009, 05:38 PM | #40 |
IC2(SW)
Name: Kerry
Location: Pensacola
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