Prepare
Warning: Gasoline is extremely flammable and highly explosive. Keep gasoline away from ignition sources which could result in death or serious injury. See the Safety chapter.
Warning: To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
1. Purge fuel system. See Fuel line.
2. Remove main fuse. See Power disconnect.
3. Drain fuel tank.
4. Remove seat. See Removing and installing seat.
5. Lift rear of fuel tank. See Lift rear of fuel tank.
6. Detach fuel line at quick disconnect fitting. See Fuel line.
7. Remove fuel pump connector. See Fuel pump assembly.
Remove
1. See Figure 6-5. Detach vent line (2) from fuel tank.
Note: Pry overlap of cross-over tube clamp (1) to remove. If clamp must be cut, use a sharp high-quality wire cutter.
2. Detach cross-over tube.
- a. Discard clamp (1).
- b. Detach cross-over tube (3).
3. See Figure 6-6. Remove fuel tank.
- a. Slide fuel tank back and away from front mounts (2).
- b. Remove fuel tank.
Install
| PART NUMBER | TOOL NAME |
| HD-41137 | HOSE CLAMP PLIERS |
1. See Figure 6-6. Install fuel tank on front mounts (2).
2. See Figure 6-5. Attach cross-over tube.
- a. Attach cross-over tube (3).
- b. Install new clamp (1) using HOSE CLAMP PLIERS (Part No. HD-41137).
3. Attach vent line (2) to fuel tank.
Figure 6-5. Cross-over Tube: 1. Clamp; 2. Vent line; 3. Cross-over tube
Figure 6-6. Front Mount: 1. Bracket; 2. Front mount; 3. Stud
Complete
1. Attach fuel pump connector. See Fuel pump assembly.
2. Attach fuel line at quick disconnect fitting. See Fuel line.
3. Install fuel tank. See Lift rear of fuel tank.
4. Install seat. See Removing and installing seat.
5. Install main fuse. See Power disconnect.