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  • Gas Tank Removal????

    Hi guys. I have just finished installing new pipes on my road star and now I want to re jet the carb. I can't figure out for the life of me how the heck the gas tank comes off. I have watched multiple videos. I removed the 10mm long bolt from the seat side of the tank. I then removed the 3, 5mm allen screws from the dash but it is extremely tight and I see zero wire connectors under the dash. The only wires are running directly to the instrument screen for the mileage and it looks to be hard wired so you can't tamper with it. Where are these 2 wire connectors?? The tank is also very tight with no play from the front. I can lift up on the back of the tank but just an inch or so. What am I missing? Any help would be appreciated. Thanks!

  • #2
    The tank slides rearward to remove. There are two brackets on the front of the tank that slip over rubber guides. Just remove all of the fuel lines, electric connections and vent tube and slide the tank rearward. This is very common with a lot of motorcycles.

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    • #3
      This might help.

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      • #4
        You don't have to unplug the wires if you lay a rag over the bars and let the speedo rest there.
        With enough beer you can do anything...D.Pate

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        • #5
          once you pull the tank rearward you will find the dash panel plugs tucked away under the tank. They can be a PITA to get apart with the way they are clipped/locked together but look real close and you will figure it out.

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          • #6
            Also after removing the 10mm long bolt from the seat side there is a green electrical connector beside it dont forget to disconnect it ( I have forgot in the past and ended up holding the tank in one hand and trying to separate the connector with the other hand).
            "It's not the destination...it's the ride"

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            • DEEPHATE
              DEEPHATE commented
              Editing a comment
              Yeah, don't forget that one! Also an empty tank is much easier to handle.

          • #7
            The tank won't lift more than an inch because those harness connectors are tucked down under the front of the tank Lift back of tank about an inch and wiggle left and right while pulling back, as it comes back lift a little more. The more you do it the easier it gets
            It's not that life is so short, it's just that you're dead for so long.---unknown.

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            • davej
              davej commented
              Editing a comment
              After I got mine off the first time I used silicone spray on the rubber tank mounts. Now it slides off real nice. First time it was stuck on the rubber mounts pretty good and took a bit of wiggle to get it off.

            • MikeyC
              MikeyC commented
              Editing a comment
              Cool, I'll have to try that.

          • #8
            Okay now I'm in a pickle. I have stripped 2 of the screws for the first bowl cover. Now what can I do? Those suckers are froze in there. I have tried lock pliers etc nothing will break then free.

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            • #9
              Needlenose locking pliers? Probably you can drill out last ditch.
              With enough beer you can do anything...D.Pate

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              • #10
                Can you cut a slot with a dremel for a flathead?
                With enough beer you can do anything...D.Pate

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                • #11
                  Just a suggestion, you can purchase Japanese standard screwdrivers or bit sets. This will save you. Most Phillip style screwdrivers will not fit tight in the screw head. Therefore when extremely tight, the driver will cam out and strip the screw head.
                  Get a pair of good wire cutters, place it diagonally across the screw and squeeze tight. Try to tighten first, then loosen.
                  If that does not work, then Dremel or hacksaw a slot into the screw head.

                  Good Luck
                  2005 Silverado Midnight Star

                  Comment


                  • #12
                    It helps to wiggle the tank as you pull it back, especially if it’s been awhile since it was removed.

                    Comment


                    • #13
                      For future reference when working on Japanese manufactured items, SbTx_Rider is correct, they don't use Philips screws they use Japanese Industrial Standard (JIS) cross head screws. The Vessel impacta driver will be your friend!

                      Click image for larger version

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                      2012 Road Star Silverado S

                      Comment


                      • roadiemort
                        roadiemort commented
                        Editing a comment
                        Or what you thought was a philips in the Yamaha tool kit that came with the bike that is in fact a JIS head driver.

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