Join Date: Jun 2008
Location: New York, NY, USA
I had the tank off my bike to install wiring.
Removed all the tupperware (plastic panels) on the front, both sides, that is the large side panels, the tank side panels and the tank cover panel. This takes less than 30 mins. Keep all the screws pressed into a piece of paper template so you can replace them where they came from as there are several lengths.
There are two fasteners securing small brackets that secure the tank towards the rear of the tank, one on each side. Loosen fasteners and remove.
There are two fasteners passing through rubber grommets and holes in the sides of the tank towards the front of the tank. Remove the bolts and watch you don't loose the rubber bits and related washers. The tank is now free to move, but may be heavy if full.
Slide the tank back and up a bit and you will see at the front of the tank the wires for the fuel pump and sender and the fuel line and return(?) The electrical connections just pull off and cannot be installed wrong. The fuel line has a rubber washer that can be damaged, causing leaks so be careful with it. Once all these are removed from the tank, Viola! You can now remove your tank. The tank is made of unobtanium-plastic and costs over $1,000US so don't drill any holes in it or use it as an anvil.
Now you can run your wires and such, keeping them clear of the places the tank rides on. I chose to sheath the wires in some protective wrap to preclude sparks and stuff from igniting the 6 gallons of fuel nestled between my legs.
In the words of all motorcycle manuals...Replacement is the reverse of removal.
The whole task of removing will take less than an hour. Putting the plastic back on will take twice as longs as taking it off. You will have screws left over, because that's what happens, just save them for next time when you won't have enough....This just happens too and keeps the universe from exploding.
2008 K1200GT, Custom Paint, Vivid Black, Aeroflow WS & Aeroguards, Givi E52 Maxia Topcase w/AdMore Lighting, Zumo 660, Suburban Footpeg Lowering, Sargent Seat
2009 R1200GS Adventure, Magnesium Grey/Black, Adventure Cases, Zumo 660, Touratech Unobtanium Accessories
1974 Norton Commando 850 Soon to be a restoration project