HOW TO: Remove fuel tank and air box 08-12 - Yamaha R6 Forum: YZF-R6 Forums
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 27 (permalink) Old 11-03-2012, 01:30 PM Thread Starter
Sometimes..........
 
bluerebel's Avatar
 
Join Date: Nov 2011
Location: Central Cali.
Posts: 3,412
Bike: 2012 R6
HOW TO: Remove fuel tank and air box 08-12

Per request, I have done a HOW TO on removing the fuel tank and the air box from a 08-12 R6.... May apply to earlier models but double check before proceeding.

Tools needed:
-5MM T-handle
-1 zip tie
-screwdriver with 1/4" driver
-4MM Allen bit for screwdriver
-#2 Phillips screwdriver.
-needle nose pliers
-pliers


Steps:
1. Remove rider seat. Remove the two 5MM Allen bolts from each side



2. Remove tank side fairings. Unscrew the two Phillips screws from each side. Make sure you pull the stop washers as well. Push forward and pull away. Be careful to not break any tabs by pulling to hard.




3. Remove the 5MM Allen bolts from each side of the tank.


4. Remove the 5 MM Allen bolt on the front of the tank.



5. Life the tank from the front. Place a towel between the air box and the triple tree and place your stilt. I use a 2x4 which works great.

My stilt lol.


6. Once the tank is propped open. You will remove one two vent hoses, two electrical plugs and once fuel line.
Remove the first vent hose using the needle nose pliers

If you have the charcoal canister, you'll have a vent hose connected here as well

Remove the electrical plugs


Remove the fuel hose. There will be gas in the line so have a towel hand. Remove the plastic clip first


Squeeze the blue buttons on both sides... Twist and pull and you hold them. They are a bit tough so be careful and make sure the tank doesn't come done

Everything disconnected from the tank


7. Remove the 2x4.... Hold the tank with one hand as you remove the 5MM bolt at the tanks hinge



8. Remove tank and place in a safe location. Be cautious not to damage anything on the bottom. Also, if you have a full tank, be careful and make sure it won't leak



9. Disconnect the electrical plugs coming from the upper injectors and the plug coming from the lower part of the air box
LOWER

UPPER


You'll need to loosen the zip tie from the frame to feed the upper plug through it. DO NOT CUT THE ZIP TIE. You simply pull on the little tab and the zip tie will loosen.


10. Disconnect the fuel hose from the upper injectors. It will contain fuel so have a towel ready, or a container.
Locked

Pull the orange clip out to unlock it, once this is done, squeeze the yellow buttons and as you do, pull and twist to remove



Zip tie the fuel hoses like so to keep them from draining fuel


11. Disconnect the hose from the bottom of the air box using your pliers



12. Next, remove a total of 11 Phillips screws from around the top of the air box.

DO NOT REMOVE THE TOP 4 ALLEN BOLTS!


13. Gently lift the upper part of the air box as you plug the fuel port. Once you remove it, turn it upside down to keep fuel from draining



14. Next, you'll loosen 6, 4MM Allen bolts from the lower part of the air box. These will loosen but will not completely come out as they have a safety catch. You'll know when they are loosened all they way. Only loosen the Allen bolts on the bottom, DO NOT REMOVE THE TWO PHILLIPS SCREWS.


15. Next, gently lift the lower part of the air box and it should come out smoothly.


If you're going to leave your work area for a bit, make sure to cover your work area to prevent any foreign object from falling into sensitive areas.



That concludes our HOW TO on removing the fuel tank and air box. If you have any questions, please feel free to comment or PM me.





If you choose to follow agg's suggestion about tilting the tank back.. This is what you do. My tank was fairly full of fuel so I used the 2x4 to help a little.





Sent from my iPhone using Motorcycle.com Free App

I dont measure life in dollar bills, I measure life with the joy I get out of it.



Last edited by bluerebel; 11-03-2012 at 08:07 PM.
bluerebel is offline  
Sponsored Links
Advertisement
 
post #2 of 27 (permalink) Old 11-03-2012, 02:31 PM
I eat my R6
 
Jaguilar513700's Avatar
 
Join Date: May 2012
Posts: 332
First...


Sent from my iPhone using Motorcycle.com Free App
Jaguilar513700 is offline  
post #3 of 27 (permalink) Old 11-03-2012, 02:32 PM Thread Starter
Sometimes..........
 
bluerebel's Avatar
 
Join Date: Nov 2011
Location: Central Cali.
Posts: 3,412
Bike: 2012 R6
:popcorn

I dont measure life in dollar bills, I measure life with the joy I get out of it.


bluerebel is offline  
post #4 of 27 (permalink) Old 11-03-2012, 02:34 PM
Suk it, Lee
 
Ryan5544's Avatar
 
Join Date: Jul 2010
Posts: 19,063
Re: HOW TO: Remove fuel tank and air box 08-12

Second? I don't get it..



Good write up.
Ryan5544 is offline  
post #5 of 27 (permalink) Old 11-03-2012, 02:39 PM Thread Starter
Sometimes..........
 
bluerebel's Avatar
 
Join Date: Nov 2011
Location: Central Cali.
Posts: 3,412
Bike: 2012 R6
Me either.


I dont measure life in dollar bills, I measure life with the joy I get out of it.


bluerebel is offline  
post #6 of 27 (permalink) Old 11-03-2012, 02:42 PM
Track=Cocaine
 
R-Silaxin's Avatar
 
Join Date: Sep 2009
Location: El Paso, TX
Posts: 13,523
Bike: 06 R-6 Deathraven
Re: HOW TO: Remove fuel tank and air box 08-12

Not bad at all... and for anyone looking... I'll throw this How-To in here as well if you need to Siphon the tank once it's off...

Pretty straight forward How-To! This will work for the 06+ R6 Non-S models...


RIP Richard Bishop. You're a great friend and someone I will never forget.
MY TRACK BUILD THREAD http://www.r6-forum.com/forums/showt...05#post2428805
MY TRACK DAY THREADhttp://www.r6-forum.com/forums/showt...655&highlight=
MY YOUTUBE CHANNEL https://www.youtube.com/user/adam2cox
MY FACEBOOK http://www.facebook.com/profile.php?...79&ref=tn_tnmn


MY XBL GAMERTAG: AmericanGingers
R-Silaxin is offline  
post #7 of 27 (permalink) Old 11-03-2012, 02:45 PM Thread Starter
Sometimes..........
 
bluerebel's Avatar
 
Join Date: Nov 2011
Location: Central Cali.
Posts: 3,412
Bike: 2012 R6
Thanks for the addition bro. Appreciate it.

I dont measure life in dollar bills, I measure life with the joy I get out of it.


bluerebel is offline  
post #8 of 27 (permalink) Old 11-03-2012, 02:50 PM
Track=Cocaine
 
R-Silaxin's Avatar
 
Join Date: Sep 2009
Location: El Paso, TX
Posts: 13,523
Bike: 06 R-6 Deathraven
Re: HOW TO: Remove fuel tank and air box 08-12

God damn I was fat when I made that video...



Nice write up though brutha! Videos are better. For the less mechanically inclined... Some people get lost even with instruction, and pictures...

RIP Richard Bishop. You're a great friend and someone I will never forget.
MY TRACK BUILD THREAD http://www.r6-forum.com/forums/showt...05#post2428805
MY TRACK DAY THREADhttp://www.r6-forum.com/forums/showt...655&highlight=
MY YOUTUBE CHANNEL https://www.youtube.com/user/adam2cox
MY FACEBOOK http://www.facebook.com/profile.php?...79&ref=tn_tnmn


MY XBL GAMERTAG: AmericanGingers
R-Silaxin is offline  
post #9 of 27 (permalink) Old 11-03-2012, 02:50 PM
Track=Cocaine
 
R-Silaxin's Avatar
 
Join Date: Sep 2009
Location: El Paso, TX
Posts: 13,523
Bike: 06 R-6 Deathraven
Re: HOW TO: Remove fuel tank and air box 08-12

Quote:
Originally Posted by bluerebel View Post
Thanks for the addition bro. Appreciate it.
You got it!

RIP Richard Bishop. You're a great friend and someone I will never forget.
MY TRACK BUILD THREAD http://www.r6-forum.com/forums/showt...05#post2428805
MY TRACK DAY THREADhttp://www.r6-forum.com/forums/showt...655&highlight=
MY YOUTUBE CHANNEL https://www.youtube.com/user/adam2cox
MY FACEBOOK http://www.facebook.com/profile.php?...79&ref=tn_tnmn


MY XBL GAMERTAG: AmericanGingers
R-Silaxin is offline  
post #10 of 27 (permalink) Old 11-03-2012, 02:52 PM Thread Starter
Sometimes..........
 
bluerebel's Avatar
 
Join Date: Nov 2011
Location: Central Cali.
Posts: 3,412
Bike: 2012 R6
Lol , it did cross my mind to do a vid but I was like **** it lol

I dont measure life in dollar bills, I measure life with the joy I get out of it.


bluerebel is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Yamaha R6 Forum: YZF-R6 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Need to Remove Fuel Tank.....How to get gas out ? standman4320 General Discussions 20 10-23-2013 09:24 AM
Remove fuel from oil dsmDIYr6 Oil and Lubrication 1 03-17-2012 03:53 PM
How do I remove the fuel pump? AeroRamer Garage / Mechanical Help 3 12-02-2011 07:51 AM
06 Yamaha R6 Fuel Tank w/fuel pump & tank cover Executiveone98 Bikes Parts For Sale 3 08-08-2010 05:24 PM
Need a help in how to remove fuel tank on 2003 yamaha r6 vartan13 General Discussions 4 03-05-2008 12:25 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome