Fuel Tank

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Warning: Gasoline is extremely flammable. Work in an area that is free of open flames and sources of sparks. Properly clean up any spilled gasoline as soon as possible.

Note: The 2006 and newer 650 models have a different fuel tank.

Fuel Tank Removal

Remove the rear fender. See the Rear Fender topic for more information.

Note: On 2006 and newer 650 models remove the following:

1. Remove the vacuum fuel pump.
2. Remove the fuel level sensor connector.
3. Remove the breather hose.
4. Remove the fuel valve vacuum hose.

Locate the fuel line.

Squeeze the fuel line clamp with needle nose pliers and slide it back. Pull off the fuel line. Inspect the fuel line for damage and deterioration. Replace it as needed.

Disconnect the fuel pump connector.

Locate the breather hose.

Squeeze the breather hose clamp with needle nose pliers and slide it back. Pull off the breather hose. Inspect the fuel line for damage and deterioration. Replace it as needed.

Locate the fuel mounting bolts.

Remove the two fuel tank mounting bolts with an 8 mm socket.

Remove the two collars. Remove the fuel tank.

Remove the mounting screw and tank cover with a #3 Phillips screwdriver.

Fuel Tank Inspection

Inspect the rubber dampers and grommet on the frame. Replace the parts if needed.

Inspect the insulation and replace if needed.

Inspect the projection and replace if needed.

Inspect the breather hoses and replace if needed.

Inspect the check valve and fuel tank breather. Replace parts if needed.

To clean the fuel tank; pour in some high-flash point solvent and shake the tank. Empty the solvent and debris from the fuel tank.

Fuel Tank Installation

Install the tank cover and mounting screw with a #3 Phillips screwdriver.

Install the fuel tank.

Locate the mounting locations.

Install the two collars.

Install the two fuel tank mounting bolts and tighten them securely with an 8 mm socket.

Locate the breather hose.

Install the breather hose. Squeeze the breather hose clamp with needle nose pliers and slide it on.

Connect the fuel pump connector.

Install the fuel line onto the fuel pump. Squeeze the fuel line clamp with needle nose pliers and slide it on.

Note: On 2006 and newer 650 models install the following:

1. Install the fuel valve vacuum hose.
2. Install the breather hose.
3. Install the fuel level sensor connector.
4. Install the vacuum fuel pump.

Install the rear fender. See the Rear Fender topic for more information.