Plastic fuel tank

2 -	Plastic fuel tank

1

2

3

4

5

6

7

8

9

10	Cable guide

11

12

13

14	Filler plug

15

16	Panel (BLACK)

17

18

19

20

21

22	Hose guide

23

24	Breather hose

25	Self-tapping screw

26	Complete flange

27

28	Thermistor

29

30

31

32

33

34

35	Quick-release fitting

36	Hose guide

Spare parts catalogue


Inlet dict
Fuel tank
Fuel system

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the fuel tank

Remove or lift the seat (Sect. E 3, Removing the seat).

Lift the fuel tank hook (4).

Lift and drain the fuel tank.

Withdraw the hose (24) in an upward motion. Leave hose hanging on the couplings of the fuel tank breather (20) and drain (21) hoses.

Detach the connector (A) of fuel sensor and fuel pump from the main wiring harness.

Disconnect the quick-release fittings (35) of delivery hose (C) and return hose (D) from the flange and leave the hoses connected to the throttle body.

Remove the split pin (8), slide out pin (7), keep bushings (5) and washers (6), then remove the tank from the frame.

Removing the filler plug unit - plastic tank

Remove the filler plug unit from the fuel tank as follows:

open the filler plug.

Unscrew the 3 outer screws (13) fixing the ring nut to the fuel filler recess.

Unscrew the anti-theft screw (12) inside.

Remove the complete filler plug (14).

The filler plug is fitted with a breather cap (E).

When fitting a new breather cap, apply an even film of speed bonder all round the cap (E) groove.

Install the cap. Make sure it becomes properly seated in the seat in the recess.

Refitting the filler plug unit - plastic tank

Refit the complete plug (14) in the tank housing and tighten the screws (13) and (12) to the specified torque (Sect. C 3, Frame torque settings).

Replacing fuel tank flange

Release the six retaining screws (27) of the fuel tank flange (26). Remove one every two screws. The three screws left in place will help lift off the flange (26).

Remove the complete flange (26) from the reservoir.

Release the clamps (31) and (33) at the fuel filter (34) with the suitable tool available on the market.

Detach the filter from the connection hoses and replace filter.

On refitting, clean off any build-up or scale accumulation from all components.

Position the new filter (34) with the arrow stamped on the outer casing pointing towards the flange.

Change the flange O-ring (30). Grease the new O-ring and reverse the removal procedure to refit.

Make sure to fit the flange in the correct mounting position: the arrows and FRONT must be pointing in the direction of travel of the vehicle.

Tighten the screws (27) to the specified torque (Sect. C 3, Frame torque settings).

Refitting the plastic fuel tank

Place the fuel tank in the frame and connect the following components:

-	connector (A) of fuel pump and fuel sensor wiring;

-	Delivery hose (C) quick-release fitting (35);

-	Return hose (D) quick-release fitting (35) ;

-	breather hose (20) and drain hose (21).

Position the tank to the bracket (10).

Position the pin (7) to the bracket (10) with bushes (5) and washers (6). Lock with the split pin (8).

Lower the tank. Make sure the hoses do not become trapped and secure the tank with the hook (4).

Plastic tank drain breather hoses routing

Fuel hoses routing - from plastic fuel tank to throttle body