919 Tank Removal - Wrist Twisters
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post #1 of 11 Old 10-23-2006, 06:40 PM Thread Starter
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919 Tank Removal

I will soon be replacing my 06 919 tank. I was wondering if anyone has done this before and could give me any tips. I raised the tank this weekend and it doesn't look too hard. Not sure how I'm going to drain the tank yet so any advice would be appreciated. I don't have the service manual either but hey when does that ever stop a guy? I will be selling the old tank on ebay probably next week if anyone is looking for one. My friend dumped my bike in my driveway. The tank did not cave in at all and only has a 1" scratch near the right side Honda decal. Rest of tank is cherry. Thanks.

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post #2 of 11 Old 10-23-2006, 07:05 PM
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How much you selling for and got any pics?

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post #3 of 11 Old 10-23-2006, 07:22 PM
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It's pretty straight forward. I had a service manual but it isn't necessary for the removal/install. Start to finish it should take about 1 Hr. to complete, Fuel Hose, Return hose, 2 Vent hoses and Maintanence wire is all you remove.

I recommend getting #21 Gasket Base and #5 Fuel Return Filter from bikebandit.com or Honda Dealership. The stock gasket is rubber and I didn't have enough miles on it to warrant buying a new one but I did anyways because it's cheap for piece of mind. If you have any questions about it shoot me a PM. Good luck

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post #4 of 11 Old 10-23-2006, 07:26 PM
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Fuel tank removal per manual

page 1 of 4


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Hope this helps!
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post #5 of 11 Old 10-23-2006, 10:05 PM Thread Starter
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Thanks AJ. You rock dude. Still looks like a pain in the ass! How do you relieve the fuel pressure on page 5-44? I guess I need page 5-47 too for the fuel pump removal but that looks like it is only 6 bolts?

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post #6 of 11 Old 10-23-2006, 10:12 PM
 
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Trust me it's easy. The only problem I have had, and I have done 2 tank swaps, was getting the fuel out of the tank. If you have a way to suck the gas out, then all you have to do is remove a few hoses and bolts. Swapping the gas cap and fuel pump assembly is easy, only a few bolts, that's it. I think there is one electrical connection (for the low fuel warning light), it is made to disconnect so it is simple pull out, plug back in.
Like I said, it is really easy, don't worry about not having a shop manual.

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post #7 of 11 Old 10-26-2006, 08:06 PM Thread Starter
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Scratch Picture

Here is a picture of the scratch.

http://www.putfile.com/pic.php?img=3816292

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post #8 of 11 Old 10-26-2006, 08:08 PM
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I got your email. how much are you looking for the tank?

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post #9 of 11 Old 10-26-2006, 08:12 PM Thread Starter
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Tank Bid

I think I'm going to start the bid at $100 USD. The new tank is arriving tomorrow so I haven't even pulled the old one off yet.

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post #10 of 11 Old 10-28-2006, 05:08 PM
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The easiest way is yes, undo those six bolts of the sending unit and then there are two hoses that you just pull off and don't forget the safety cable on the underside of the nose of the tank too, you'll find it. As far as getting the gas out...I can't help ya there, my tank had a @#&*^! hole in it so there wasn't any gas left in it when I took it off

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post #11 of 11 Old 10-29-2006, 06:02 AM
 
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Take it out for a good day of riding till the fuel light comes on...

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