Manual - Chapter 5 - Fuel & Oil

5: Fuel tank components: removal and refitting

  1. Refer to Section 2 of this Chapter for notes on precautions to be observed when servicing any part of the fuel system.
  2. Open and raise the dual seat, then remove both side panels. See Chapter 7 - Frame & Forks
  3. On K100 and K75 C, K75 T and K75 models remove the radiator covers. On K1 00 RS models remove the left-hand knee pad. On K100 RT and K100 L T models remove the left-hand knee pad, storage compartment and compartment holder. See Chapter 7 - Frame & Forks.
  4. Relieve any residual fuel system pressure. See Section 3.
  5. Remove from its frame clip and disconnect the fuel tank wiring connector plug.
  6. On early 100 models remove the single bolt securing the tank rear end to its rubber mounting. On all other models use a pair of pliers to withdraw the flat clip securing each of the two tank mountings. Lift the tank at the rear and disconnect. on early models only, the tank vent and fuel overflow hoses; note carefully where each hose is fitted. Remove the tank wiring lead from the frame tubes.
  7. Placing a rag to catch any spilt fuel as described in Section 2, disconnect the fuel feed and return hoses either from underneath the tank front left-hand side or at the fuel rail (feed hose only). Carefully lift the tank at the rear then pull it backwards to disengage the front mounting rubbers. Be very careful not to damage its paintwork, especially on machines with fairings.
  8. As soon as the tank is clear of its front mountings, lift it to one side so that the pressure relief hose (US models only, where fitted) can be disconnected and removed. Withdraw the tank, taking care not to spill any fuel (later models only).
  9. On refitting, be very careful to connect the various hoses to their correct stubs. On early models the overflow hose is fitted to the stub which passes up to the filter cap recess drain hole, while the vent hose is connected to the stub which exits inside the tank, at the top. The fuel return hose is connected to the front left-hand stub and the feed hose to the rear left-hand stub. On US models the pressure relief hose (where fitted) is connected to the remaining stub. Check carefully that all hose clamps are securely fastened and that all hoses are correctly routed with no kinks or sharp bends.
  10. Applying a smear of lubricant to the mountings, manoeuvre the tank into place, connecting the hoses at the appropriate moment. Check that the tank is fully engaged on its front mountings, then lower it into place at the rear. Again, check carefully that the hoses are not kinked or distorted before fastening the tank rear mountings. On late models note that the overflow and vent hoses are connected to a funnel which is clipped to the frame tubes under the tank stubs.
  11. Ensuring that it is correctly routed, refit the fuel tank wiring lead and connector plug to the frame clip.
  12. Check that all hose clamps are securely fastened before starting the engine.
  13. Note: If the vent hoses are blocked through obstructions or through being kinked or trapped due to careless installation, pressure can build up in the tank to the point where the tank bulges outwards on the left-hand side, fuel sprays out whenever the filler cap is opened and the engine performance is affected. Be very careful to check that all hoses and vent tubes are correctly re-routed whenever the tank is disturbed.


5.5a Remove fuel tank wiring connector from its retaining clip ...

5.5b ... and disconnect to release tank wiring - ensure catch is fastened correctly on refitting

5.6 Remove clips securing tank mountings on later models - early models use singles bolt

5.7a Disconnect fuel feed and return hoses from unions under tank front left-hand end

5.7b Note that fuel feed hose can also be disconnected at fuel rail, if required

5.7c Check tank front mounting rubbers and insulating material whenever tank is removed

5.10a Lubricate tank mounting rubbers on reassembly

5.10b Check very carefully routing of tank hoses - overflow and vent hoses are directed into a funnel on later models