REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Relieve the fuel system pressure.
- For safety purposes, disconnect the negative battery cable.
- Siphon as much fuel as possible from the fuel tank, using the appropriate siphoning equipment.
Having the fuel tank as empty as possible will make removal safer and easier.
- Remove the lower half of the seat, and remove the fuel pump access cover.
- Raise and safely support the vehicle.
- Disconnect all hoses, lines and electrical connectors from the fuel tank assembly.
- Remove the fuel tank protection panels.
- Safely support the fuel tank, and then remove the fuel tank straps.
- Carefully lower the fuel tank from the vehicle.
Keep in mind a small amount of fuel will be in the fuel tank; keep a drain pan and some rags handy to contain any excess fuel.To install:
Replacing all flexible fuel lines connecting to the tank is a good idea, since they are easily accessed while the fuel tank is removed.
- Raise the fuel tank into position and support it.
- Swing the fuel tank straps upward, and torque the strap bolts to 27-37 ft. lbs. (37-49 Nm.).
- Install the fuel tank protectors to the fuel tank and/or the chassis.
- Connect all hoses lines and electrical connectors to the fuel tank assembly. Always use new hose clamps to prevent leaks.
- Pour one or two gallons of fuel into the tank.
- Connect the negative battery cable.
- Start the engine, and check for any fuel leaks.
- If all the connections are secure, install the fuel pump access cover and the rear seat.
Keep in mind that the engine may take longer to start, since the fuel system has to pressurize. Be sure the battery is in good condition.