Join Date: Jan 2011
Location: Calgary Alberta Canada
The fuel tank is actually very easy to remove. First thing to do is ride it until you've used up most of your fuel and get home with less than a 1/4 tank of fuel. This is the most fun part about any mod that requires the fuel tank to be removed. I would suggest riding someplace for good bbq or your favorite type of food / entertainment establishment then return home. Let your bike cool down before doing anything to it. There is far less chance of personal injury (being burned). Lastly an empty fuel tank weighs far less than a full one.
I would also suggest picking up a service manual for your year of bike. The instructions in the manual are clear and simple, from what I can remember, no special HD tools are required to remove the tank from the bike.
Believe me, if I can do it, anybody can. Save the labor costs of the dealer tech and do it yourself. It will give you much satisfaction to work on your own bike.
Some things to have on hand when you do want to tackle this easy modification
1. Good bench or table that you can lay out parts on as you take them off. I usually like to cover that bench or table with a moving blanket, this is where I will place all painted or chrome parts that come off
2. Ziplock bags, sandwich size. I put all small hardware fasteners in a zip lock bag and label it for what they attach, e.g. fuel tank bolts or saddle bag bolts or tank dash bolts; especially if I know that I won't be able to complete the job in one session.
3. Good selection of basic tools that are used on a Harley, Allen wrenches, regular and deep 3/8" drive SAE socket set comes in handy, Torx screwdrivers and or bits.
4. Torque wrench in in/lbs and ft/lbs. All torques for all fasteners on your bike are listed in the back of the service manual. There is no excuse for "over tightening" a fastener
5. Patience, patience, patience. This virtue will serve you best.
You can do it and you should do it for these easy modifications. This is the best way to get to know your bike and the satisfaction of doing it yourself will lead you to do more and more work on your bike building your confidence in your own mechanical abilities.
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