Gas / Fuel Tank removal

[Fz6Sa]

Since it's so often discussed on this forum, I figured I would post a how to on removing/lifting the tank without removing the fairings.
All pictures are from a 2006 model.

Ok; here we go:

First of all, here's what you will need to complete the process:

1 Allen key (5mm), 1 Flange key(?) 10mm, a pair of clamps:
(I also use an extension piece but that is not needed)

First we have to make sure we don't spill any fuel, so we have to block 2 overflow fuel hoses.
Both hoses are found under the bike, right side, where the center stand is mounted.
The can be identified by the white stripe on them, and the facts that they are cut of in an angle:

To block them off, we are going to use the clamps:

First bend the hose:

Then apply clamp:

Repeat on both hoses:

Edit: FI fix 600riders.com

 

[Fz6Sa]

Having both hoses securely clamped up (If you have any doubt, place a plastic bucket under them),
we can now remove the bolts holding the tank:

First the front ones:

Make sure you cover the tank with a piece of cloth before unscrewing the bolts! (Protect if from scratches):

Proceed to remove both front bolts in same manner. Once removed you should have two bolts with spacers:

Now, for the rear bolt. To access it you have to remove the seat first:

Again, cover the tank with cloth before using tools:

You should by now have removed these 3 bolts:

Edit: FI fix 600riders.com

 

[Fz6Sa]

By now you can lift up the rear of the tank, while sliding it backwards.
Don't lift to high, just enough to get it over the bracket where the rear bolt was mounted:

Allowing the tank to rest on top of the rear bolt bracket, make sure is been moved enough backwards for the front of the tank to clear the fairing:

Now lift the front of the tank so its over the fairing, and slide the tank forward again, until the rear bracket is in the correct position again.
Then rest the front of the tank on the fairing (Use some cloth between the fairing and the tank):

Now reinsert the rear bolt (no need to tighten it, just "finger-screw" it in:

Edit: FI fix 600riders.com

 

[Fz6Sa]

You can now freely lift up the front of the tank, using the rear bolt as a hinge.
Use any object to hold the tank in upright position(I found that a wine bottle is perfect ):

Top view:

Reverse process to put the tank back in place.
Pay attention when you put the tank back down that you don squeeze any of the hoses under the tank.

When removing the clamps in the end, place a plastic bucket under them to catch any residue the might have build up in the hoses:

The whole process takes about 15 minutes once you get a hold of it.
I know it can seem like many steps, but just take your time, and be sure not to forget any, and anybody can do this.
Edit: FI fix 600riders.com

 

[steveindenmark]

Thanks for this. Is your bike the same as mine.

Steve

 

[Fz6Sa]

Thanks for this. Is your bike the same as mine.

Steve

I think so ...,- Mine is a FZ6SA from 2006.

 

[mlevins77]

If you want to skip the step of removing the rear bolt, you can simply remove the inside fairing liners by removing the two bolts that are visible on the outside of the fairing. Put your sheet/paper/soft object to protect your tank in there and slide the liner out like a puzzle piece. After this there is no interference with the fairing.

Just another way of building a bridge.

Ride safe, ride often.

Cheers,

Mike

 

[Fz6Sa]

If you want to skip the step of removing the rear bolt, you can simply remove the inside fairing liners by removing the two bolts that are visible on the outside of the fairing. Put your sheet/paper/soft object to protect your tank in there and slide the liner out like a puzzle piece. After this there is no interference with the fairing.

Just another way of building a bridge.

Ride safe, ride often.

Cheers,

Mike

Many of the members seems to struggle with the removal of the inner fairings, -
that's why I made this write-up

But thanks :thumbup:

 

[Motogiro]

Great Post. Thank you!

 

[Nelly]

Many of the members seems to struggle with the removal of the inner fairings, -
that's why I made this write-up

But thanks :thumbup:

Brilliant mate,

(Reputation must be spread around before you can give it to FZ6Sa)

I tried it after you mentioned it a while a while back. It works for me.


Nelly

 

[Fz6Sa]

Brilliant mate,

(Reputation must be spread around before you can give it to FZ6Sa)

I tried it after you mentioned it a while a while back. It works for me.


Nelly

yeah, - I know I've mentioned quite a few times , - I just figured that the pic's could help especially new riders/modders.

And thanks for the almost rep :thumbup:

 

[madmanmaigret]

Brilliant mate,

(Reputation must be spread around before you can give it to FZ6Sa)

I tried it after you mentioned it a while a while back. It works for me.


Nelly

Don't worry, Nelster, I got you covered on the rep!

Thanks FZ6Sa!

 

[Fz6Sa]

Don't worry, Nelster, I got you covered on the rep!

Thanks FZ6Sa!

WOW!,- THX!!:rockon::rockon::rockon:

 

[djsegura]

By now you can lift up the rear of the tank, while sliding it backwards.
Don't lift to high, just enough to get it over the bracket where the rear bolt was mounted:

Allowing the tank to rest on top of the rear bolt bracket, make sure is been moved enough backwards for the front of the tank to clear the fairing:

Now lift the front of the tank so its over the fairing, and slide the tank forward again, until the rear bracket is in the correct position again.
Then rest the front of the tank on the fairing (Use some cloth between the fairing and the tank):

Now reinsert the rear bolt (no need to tighten it, just "finger-screw" it in:

Good tip on putting the pivot bolt back in to work, I just removed my tank to get it repainted, so will keep this in mind when doing future work under there.

 

[ReblTeen84]

Thanks! I've been trying to find a better way of getting the tank up, since this spring the Fizz is getting a battery replacement and battery tender leads added.

 

[jniedermeyer]

as a reminder, use some blue loc-tite upon re-install of all bolts and screws.

 

[Fz6Sa]

Just did an edit to reinsert the pictures in this thread,- guess they were lost in "The Big Crash".

 

[Andz]

Clamping the hoses is a great idea if you are going to work on a carpet!

 

[Fz6Sa]

Clamping the hoses is a great idea if you are going to work on a carpet!

With the gas-prices today, - I don't wonna spill a drop!!

 

[Perfj]

Nice and informative information.
Normally I would remove the battery for the winter. Always did so with my SV650.
I got my FZ6 August last year, but I actually gave up removing the battery, and bought a triggle charger in stead. Now I know how to solve the problem. Thanks.
:cheer: