2002 California EV Gas Tank removal

[Brooksr13]

Hi All,

Could use some help here, I need to remove the Gas Tank to replace the air filter and having removed the rear bolt, expected that I could slide the tank to the rear and then disconnect the remaining hoses and electrical connections. The tank will not move, what have I missed here????


Mark

[oldbike54]

 Are you lifting the rear of the tank up a bit before pulling back .

  Dusty

[Brooksr13]

Yes I am

[guzzisteve]

Pick up the back a few inches, pull back as you wiggle it side to side. Rubber pucks are dry & tight to the inside of tank.  Before you get it back too far, lift up higher and reach up under it, there is a hose connected strait under fuel cap for it's area drainage, just pressed on.

[Kiwi_Roy]

There are two hoses at the front, a breather and the fuel return from the pressure regulator.
Try not to remove the tank if it's more than about 1/2 full or fuel will spill out the return connection.
Do it outside, no matter how careful you are there will be fuel spilt.

[Rich A]

If it is like the 2000 Calis (exterior fuel pump) the allen is the only fastener that holds the tank in place. Disconnect the fuel line before trying to remove the tank--that may be what is keeping the tank from moving. Lift the tank and unplug connectors (make sure you don't mix them up), then wiggle the tank side to side. It's possible that the rubber pieces have glued themselves in place, so this may take quite a bit of force.

Rich A

[guzzisteve]

When you get it off, don't set it on the lektrik fuel shut off !! If wires are brittle they will crack. Put a block of wood under the back tab.

[pehayes]

Once you get it off, try to blow air through the "moat drain" which is the tube down in the middle of the tunnel.  The drain gets clogged and then lets rain/wash water into the tank and forms rust.

Patrick Hayes
Fremont CA

[creaky99]

I had the same problem 1st time I removed the tank, the rubbers were stuck to the tank pockets. I sprayed in some silicone lube, wiggled the tank and it finally came loose. If the rubbers are becoming brittle, there are several rubber conditioners on the market that might work to make them more pliable. I have used Sil Glyde on rubber for years, it works pretty well.

[papatom]

Just replaced the air filter on my 02 EV.  Removed rear bolt, disconnected fuel line to pet cock, electric connection to low fuel light? return line hose clamp under front of tank, and vent line.  Couldn't pull the return line completely free, but got tank back far enough that I could get the tank high enough to get to the allen bolts on ab lid. It was a pain but doable with one person.

[rodekyll]

I fixed that problem the first time I had my tank off.  I extended the lines and added marine fuel line quick disconnects.  They work like air hose couplings.  Now I don't have to tinker with that stupid return fitting or the supply side either.  I just pick up the tank, reach underneath and pop them free.  They're self-sealing on both sides so it's a drip free process and the tank doesn't spew if there's gas in it.

[creaky99]

I fixed that problem the first time I had my tank off.  I extended the lines and added marine fuel line quick disconnects.  They work like air hose couplings.  Now I don't have to tinker with that stupid return fitting or the supply side either.  I just pick up the tank, reach underneath and pop them free.  They're self-sealing on both sides so it's a drip free process and the tank doesn't spew if there's gas in it.

Great idea!   :BEER: It's on the list.