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.
-1 zip tie
-screwdriver with 1/4" driver
-4MM Allen bit for screwdriver
-#2 Phillips screwdriver.
-needle nose pliers
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
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.
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.
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