Removing gas tank

Hypersonny · May 13, 2019

Hello,

I want to install a new K&N airfilter in my Hyperstrada 821, so have to remove the gastank.

I'm following these instructions to get here naked:

https://youtu.be/HiwyfaB2J04

All works well untill I have to remove to gastank, I can't seem to pull the hoses of at the bottom. Is there somekind of trick to do this?

Thanks!

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gatdammit · May 13, 2019

Check my thread on "RapidBike Evo" install. Pretty sure I detailed the tank removal or linked video I used to do it.

Did you disassemble and remove the fuel pump and lines under the seat? The seat lock mechanism will give you trouble so recommend removing that, more so on re-installation. The main fuel line is wedged into a groove under the tank. Must remove the breather vent line near the cap, too.

Some will say you don't have to remove the bars but it makes things easier. I've pulled the tank a few times and always remove the bars.

appliance821 · May 14, 2019

The hoses at the bottom are quick release. Under the plastic housing near the top of the shock.

Also remove rubber things that the front sides of the tank hook on to.

Wedge past the seat lock.

Never had to remove handlebars myself.

edgary · May 14, 2019

appliance821 said:
The hoses at the bottom are quick release. Under the plastic housing near the top of the shock.

Also remove rubber things that the front sides of the tank hook on to.

Wedge past the seat lock.

Never had to remove handlebars myself.

This is the advice I was going to give. I spent hours trying to get the back of the tank to pivot out of place enough to lift it (after disconnecting everything) to no avail. Then I removed the rubber stays onto which the tank pivots, and lifted it straight up. I regretted not thinking about that before instead of trying to make the instructions in the manual work.

appliance821 · May 14, 2019

edgary said:
This is the advice I was going to give. I spent hours trying to get the back of the tank to pivot out of place enough to lift it (after disconnecting everything) to no avail. Then I removed the rubber stays onto which the tank pivots, and lifted it straight up. I regretted not thinking about that before instead of trying to make the instructions in the manual work.

Took me three tries before I said screw it. LOL

gatdammit · May 14, 2019

My problem was always getting it back in past the seat lock. Bent it pretty bad.

edgary · May 14, 2019

appliance821 said:
Took me three tries before I said screw it. LOL

It took me about 3 hours before I changed tactics...

gatdammit said:
My problem was always getting it back in past the seat lock. Bent it pretty bad.

... I think I even removed the panel where the seat lock is, because I couldn't go past it freely.

philthymike · May 15, 2019

Don't forget about the big fat washer for the rear bolt when putting it back together. It's really fun getting it to stay put.

gatdammit · May 16, 2019

and that damn fuel pump cover! I literally wasted an entire day trying to get the fuel line coiled back in correctly and trying to get those damn cap nuts back on. Think I lost two of the nuts last time I reinstalled it.

appliance821 · May 16, 2019

Once you figure it all out - and again, the key for me was removing the rubber pucks up front - it is a matter of 20 minutes next time. As with everything else mechanical, it's a matter of being systematic and patient... and having a small ziptie for the cable that attaches to the plastic hose cover.

edgary · May 16, 2019

True. We're making it sound harder than it really is, but that's just because we're venting about lessons learned.

gatdammit · May 16, 2019

The blue breather vent near the filler exploded on my last install. I duck taped it. It's got tiny, fragile tabs and is spring loaded. Recommend being very careful when handling the breather line.

Hypersonny · May 24, 2019

Ok, so started working on my bike.

Stuck at this part:

One of the screws came of perfectly, but the other one keeps turning...

Any solutions?

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appliance821 · May 24, 2019

They are studs that I think go into a metal insert in the plastic of the tank. Only the nuts should come off. I would try some penetrant on the nut, then trying to hold the stud while trying to loosen the nut. Not a simple task as it's kind of buried. My guess - and I'm only guessing - is that the metal insert in the tank is spinning.

kuksul08 · May 24, 2019

just unscrew it a bit and the whole stud will come out with the cover. Then you can figure out how to lock the stud into where it should be.

appliance821 · May 24, 2019

Also - there are 3 nuts to remove

gatdammit · May 27, 2019

wait till you have to Helen Keller those little *******s back on...I got psycho laughing mad it took me so long to get them all to bite my first time. If you can't get enough bite, the hose inside the pump cover is not coiled correctly.

Removing gas tank

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