Roadstar Tank Removal

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Written by NoPork.com   
Friday, 11 June 2004


NoPork.com

Reprinted by Permission from NoPork.com

One rider tells how he removed the tank on his Roadstar.

The tank is pretty easy to remove... The hardest part of removing it was unplugging one of the meter assembly coupler plugs.

The "meter assembly" is a fancy name for the chrome piece on top of your tank that holds the spedometer. First, you remove the 3 hex bolts from the meter assembly. If you don't have a windshield, you can probably just flip the meter assembly over your handlebars and let it hang (using a towel or blanket to protect any chrome or paint it might be hanging on). If you DO have a windshield like I do, you will probably want to disconnect the 2 plugs and completely remove the meter assembly and set it aside.

Once you have the meter assembly out of the way, you'll notice a little "stem" protruding from the top front of the fuel tank with a hose connected to it. This is the "fuel tank breather hose", and you'll need to go ahead and disconnect it from the "stem" on the tank. You'll also have to disconnect the fuel hose from the fuel petcock (make sure it is set to "OFF" before you do this!). Another note about disconnecting the fuel hose -- there will most likely be a little fuel left in the hose, so have a towell ready to let this drain into once you disconnect it.

Now, if you haven't already removed the rider seat, go ahead and do that now... under the seat, near the back of the tank, you'll see a green wiring harness. This is called the "fuel sender coupler", and you need to disconnect this as well.

Now, there is one long bolt near the back of the tank... remove this bolt, and the tank will be ready to remove. To remove the tank, slide it back towards the rear of the bike. You should be able to feel when you have pulled it back far enough to pull it up and off the bike...

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.


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  Comments (10)
Worked smooth!
Written by Ricki Dee, on 06-02-2013 01:25
I was removing the tank to add a wire. You suggestions were simple and 'fool' proof. Thanks a ton!
Spark plug change
Written by Fiddlekop1, on 06-09-2011 23:40
I did find it neccessary to raise the rear of the tank to get to the plugs on the rear cyl. of my 07'. Not hard at all.
Written by Lucky1, on 06-03-2011 21:44
Wow.
Written by OBMF, on 12-30-2009 04:40
On my '07 with a windshield, I didn't unplug the meter assembly (those couplers can break easy if you are monkey-fisted with tools). You will have to disconnect the green coupler at the back. Just use a small cargo net with hooks to hang the meter assembly off to the right under the handlebars. Be careful not to turn the handlebars- you can pinch the assembly! A little silicone on the knobs on the tank that go into recesses on the frame will help the tank slide in easier. A LITTLE silicone. And you can do this with a full tank if you can safely lift 65 lbs or so. Silence your tank rattle with thin rubber washers at the bolt assembly while you're at it, and use a little blue locktite on the acorn nut. 
OBMF
Install it back
Written by mfayad, on 11-01-2009 06:04
I always thought that removing the tank was a tough job, apparently it so easy compared to installing it back. I got mine off over the weekend in less than 5 minutes however took me way longer to install it back.Maybe we can find a buddy over here who can share with us his experience. 
 
cheers
tank removal question
Written by kilowatt, on 10-26-2009 16:56
My '09R* seems not to have a fuel petcock. Maybe I'm just not seeing it! The line seems a little short to just let it drain into a container with the tank in place. What's the proper procedure?
Written by Finkstar, on 07-31-2009 20:46
Another Star of information 8)
Written by knobs, on 07-12-2009 12:47
do u have to empty the tank before removal
Long Bolt
Written by exokie, on 01-20-2009 17:58
I can't seem to find that long bolt to take off so I can remove my tank. There are 2 bolts on each side of the tank. could these be the one that I must remove?
seat removal
Written by mikell, on 08-20-2008 18:57
how do I revove the seat on an 01 yamaha roadstar?

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