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HOW TO: Remove fuel tank and air box 08-12

29K views 26 replies 13 participants last post by  Fjr17 
#1 · (Edited)
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.

:cheers



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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#6 ·
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... :cheers

 
#9 ·
You got it! :cheers
 
#8 ·
God damn I was fat when I made that video... :laugh

:cheers

Nice write up though brutha! Videos are better.:secret For the less mechanically inclined... Some people get lost even with instruction, and pictures... :laugh
 
#11 ·
No worries man... I'm pretty much the same, which is why you'll only find 1 how-to video on my channel... :laugh

I've torn down that bike so many times, and put it all back together... Could do so many videos... I just never bother. But everyone appreciates the pics and walk through on your how-to's... Takes time. Thanks! If someone were to ask me directly, I'd have no probs doin any how-to's, just never bother to do them when I'm trying to get things taken care of on the bike...

:cheers
 
#16 ·
i would suggest individual paper towels into the intake ports for plugging those areas, a simple cover over the bike might not prevent everything from falling in.

also instead of a 2x4/stilt, if you have a light tank, you can use the stops on the fuel tank against the cross beam and it will hold itself up.

just a few things to add, overall nicely done.
 
#22 ·
I've subbed to all rebels how to's



I've been written a Novel on my iPhone. :lmao


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#24 ·
:werd
No need to zip tie, just a tip on keeping shit organized and clean as you work. I have to have shit organized and clean lol

But yes, any of these steps can be changed according to your preferences. There are many ways to go about this, these are just the steps I take.

:Cheers




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