2001 triumph tt600 gas tank removal

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HARLEY DAVIDSON FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Remove stock gas cap from fuel tank. 2. Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. 3. See Figure 1. Install gas cap into fuel tank. is00407 Figure 1. Screw in Gas Cap is00466 Figure 2. Note Position of Arrow on Trim Ring 4. Push down on gas cap and rotate clockwise one-eighth of a turn to lock. To unlock, push down on gas cap and rotate counterclockwise one-eighth of a turn. 5. See Figure 2. Before removing adhesive backing, note position of arrow on inside diameter of chrome trim ring. NOTE As you rotate trim ring, you will see gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. Rotation of trim ring should be minimal. 6. See Figure 3. With the arrow pointing toward front of motorcycle, rotate chrome trim ring slightly to determine best position of bottom chrome trim ring to contour of the fuel tank 7. See Figure 4. Mark position of chrome trim ring with masking tape or grease pencil. 8. Carefully cut masking tape with a hobby knife making sure not to scratch chrome trim ring or paint surface on fuel tank. 9. Peel off adhesive backing from chrome trim ring. 10. Using gas cap to center and masking tape (or grease pencil mark) to align, press chrome trim ring firmly into position for about ten seconds. 11. Peel off masking tape (or remove grease pencil mark) from chrome trim ring and fuel tank. 2 1 is00414a 1. Masking tape 2. Cut masking tape Figure 4. Align Trim Ring and Press into Place NOTE Allow adhesive trim ring to cure for about 5-7 minutes before you continue with kit installation. Install Flush-Mount LED Fuel Gauge 1. Remove the seat following the instructions in the service manual. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 2. Disconnect battery cables, negative (-) cable first. 3. Remove stock fuel gauge. Refer to service manual for instructions. 4. Insert wires down tube of fuel tank from LED fuel gauge. 5. See Figure 5 and Figure 6. Insert LED fuel gauge in the fuel tank cup

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HARLEY DAVIDSON LOCKING FUEL FILLER CAP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION 1. Prior to installing the gas cap on the vehicle, insert the key into the lock. Firmly grasp the chrome top of the fuel cap and turn the key until it stops. On right hand threaded fuel caps, turn the key counter-clockwise until it stops. On left hand threaded fuel caps, turn the key clockwise until it stops. This assures an unlocked position for the gas cap. Allow the key to return to the neutral position. 2. Remove the key and install the fuel cap on the vehicle. is00770 Figure 1. Right Hand Threaded Fuel Cap Installation NOTE When installing the fuel cap, rotate the cap one full turn past the audible click. This automatically positions gas cap to lock position. A properly locked/installed gas cap will rotate freely in both directions. Failure to do so will give an incorrect assumption that the fuel cap does not work properly. REMOVAL On right hand threaded fuel caps, insert key, and while holding the gas cap in place with hand, turn key counterclockwise until it stops, return key to original position. Gas cap must rotate 270 degrees counter-clockwise before mechanism engages to allow gas cap removal. Continue to rotate counterclockwise to fully remove gas cap. On left hand threaded fuel caps, insert key and while holding the gas cap in place with hand, turn key clockwise until it stops, return key to original position. Gas cap must rotate 270 degrees clockwise before mechanism engages to allow gas cap removal. Continue to rotate clockwise to fully remove gas cap. REPLACEMENT KEYS Record the 4 digit key number stamped on the back of the key opposite the Harley-Davidson logo, in the area provided below. If a replacement key is needed, see your Harley-Davidson Dealer with the 4 digit number to order a replacement

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2002-2004 TRIUMPH BONNEVILLE AMERICA/ SPEEDMASTER CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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A.) REAR WHEEL REMOVAL- PAGE 14-16 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 12 mm bolt from rear seat section—if you have a pillion pad remove it first by removing the 8 mm bolt, slide forward and lift free of seat catch. Take a position where you can see what you are doing or you will scratch your painted surface. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-14 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 side allen head mount bolts and 2 12mm hex head top front mount bolts– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-11 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove the 12mm rear tank-mounting bolt. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface. E.) REMOVE SIDE COVERS PAGE 15-10 and 9-15 Triumph Motorcycle Service Manual 1.) Loosen and remove left side cover screws on the air filter facade— lift slightly to disengage top mounts and remove—set aside in a safe place to prevent damage to painted surface. 2.) On right side cover simply and gently pull bayonet fittings from rubber slip mounts. 3.) Secure these rubber mounts and remove for later re-assembly with the Bonneville Performance brackets.

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

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TRIUMPH BONNEVILLE, T-100 BONNEVILLE AND THRUXTON 900 CARBURETOR KIT INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 28-10-2010

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REAR WHEEL REMOVAL- PAGE 14-14 Triumph Motorcycle Service Manual 1.) Support motorcycle on center stand or center lift so rear wheel is suspended and there is clearance for removal. Use tie downs. 2.) If both wheels are raised chock the front wheel to prevent any weight shift when rear wheel is removed. 3.) Remove chain guard. 4.) Remove caliper and support so there is no strain on the brake line. 5.) Remove both silencers from exhaust headers. 6.) Remove axle nut and washer—support or chock rear wheel—and slide out axle. 7.) Disengage chain from sprocket and hang over swing—use soft cloth to protect swing arm from scratches that will occur if you do not cover. 8.) Lower wheel to the ground and collect spacer and caliper support arm and all fasteners for re-assembly. B.) REMOVE SEAT PAGE 15-9 Triumph Motorcycle Service Manual 1.) Remove the 2 allen-screws from rear seat section. 2.) Lift seat from the rear and slide backwards to disengage tongue– collect all fasteners for re-assembly. C.) REMOVE REAR MUD GUARD PAGE 15-13 Triumph Motorcycle Service Manual 1.) Disconnect battery and remove from motorcycle. 2.) Disconnect electrical connectors on the underside of the mudguard. 3.) Support fender from beneath and remove the 4 Torx head screws– collect all fasteners for re-assembly. D.) REMOVE FUEL TANK PAGE 9-10 Triumph Motorcycle Service Manual 1.) Turn off fuel tap. 2.) Remove fuel line at the tap connection. 3.) Remove both rear tank-mounting bolts. 4.) With assistance from another set of hands support tank at the rear and lift so that the breather line is visible on the right side of the underside of tank—remove and plug line. 5.) With tank raised and supported at the rear slide backwards— disengaging it from the front mounting rubbers—set tank aside in a safe place to prevent any damage to the painted surface

2001-2003 XV16 Fuel Pump and Carburetor Removal

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Filed Under (Yamaha) by admin on 31-12-2011

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Disconnect the carburetor fuel line hose at the fuel pump. •Disconnect the fuel pump wire coupler. •Remove the choke cable from fuel pump bracket. •Remove the upper engine mount, leaving the fuel pump attached to the mount. •Disconnect the TPS and carburetor wire couplers.       Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws. PAGE 3 of 12 HIDDEN 6mm SCREW 6mm BOLT UPPER ENGINE MOUNT/ FUEL PUMP CARBURETOR PAGE 4 of 12 Right-Hand Footrest Removal: •Disconnect and remove the brake light switch. •Remove the forward-most tie wrap around the brake hose and frame. •Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: •Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting. Air Injection System (AIS) Removal: •Remove the electric starter motor. •Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. •Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. •Remove the three Phillips head screws holding    the AIS assembly on the frame. •Remove the AIS assembly from the left side. FOOTREST ASSEMBLY UPPER BANJO BOLT AIS AIR FILTER AIS ASSEMBLY
PAGE 5 of 12 Transfer Case Removal: •Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. •Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. •Remove the drive pulley cover and remove the drive pulley nut. •Loosen the drive belt tension. •Remove the drive pulley, inner cover, collar, and O-ring. NOTE: The collar has a bevel on its inside diameter     for the O-ring facing inward and a bevel on the outside diameter facing the pulley. •Remove the drive and driven sprockets with chain as an assembly. •Remove the collar and O-ring. NOTE: Collar has a bevel on its inside diameter that faces inward for the O-ring. •Remove oil tank filler neck. •Remove the relay bracket on the right-hand side. NOTE: Leave the relays connected. Simply move them out of the way to allow room for transfer case removal. •Slide the transfer case out from the right side.

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

2000-2002 Aprilia Mille INSTALLATION INSTRUCTIONS

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Filed Under (Aprilia) by admin on 26-10-2010

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1) It is a good idea to use Blue Loc-tite on all bolts you are about to remove and replace. 2) This kit has extremely close tolerances and in order for all the parts to clear the triple clamp and gas tank, you will probably have to loosen and align most of the associated bolts. We have tried very hard to make this as compact as possible but we know the factory tolerances vary from bike to bike. Be patient, the results are worth it. 3) Remove both front fuel-tank retaining bolts. You will use the longer bolts provided in our kit. 4) Install the frame bracket (part #22-6036-03) that mounts to your front (2) tank bolts holes. The frame bracket sits on top of the stock tank spacers. The frame bracket is offset. This means it fits correctly only one way, with the offset toward the triple clamp, part numbers facing forward, (see photo below). Due to the tight clearances on this model you’ll want to be sure the frame bracket does not make contact with the tank itself. It’s easier to start the tank bolts if you lift up on the tank slightly, while starting the new bolts into their threaded hole. Tighten the new tank bolts to 6 ft lbs. and use Loc-tite. 5) Remove the large 14mm Allen nut and washer that holds your triple clamp on. You will not re-use either one. 6) Install the new “Triple clamp damper mount” Part # 22-2925-00 into the recess area where the stock Allen head bolt was sitting. There is a machined recess or built-in-washer on the bottom of our mount to match the recess on your triple clamp. The 2 nubs that hang down, should match the rear contour of your triple clamp precisely. Use loc-tite and retighten the new 14mm Allen nut provided to your factory torque specs, usually a minimum of 35 ft lbs. and maximum of 85 ft. lbs. Do not use the stock washer that was under the original 14mm nut. 7) Grease the tower pin and drop it in the tower pin hole portion of the frame bracket. The tower pin is designed to “float” and requires no retaining devices. Keep the tower pin lightly greased! It should not touch the gas tank on the bottom side. 8) Install the stabilizer using the (2) 6×20 Allens with the slot in the link arm matching the tower pin. 9) Since the tank is rubber mounted at the rear, you want to be sure it won’t push forward and rub the frame bracket. After riding the first time, be sure the tank has not shoved forward by your body making contact with it. Remember, under heavy braking your entire body weight is pushing the tank forward. Until you have verified sufficient clearance between the tank and the tower pin, it might be smart to put something between the tank and tower pin to protect the tank. 10) Read your damper manual for initial settings on the controls. The damper is infinitely adjustable and totally up to the user to find their preference. Start with softer (counter clockwise) settings. Normally where we set the unit, at 8 clicks out on the base valve, is a good starting point.

Ducati Hypermotard Large Fuel Tank Installation Instructions

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Filed Under (Ducati) by admin on 26-10-2010

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REMOVING THE OEM FUEL TANK GO FOR A RIDE The best way to remove fuel from your original fuel tank is to RIDE your bike. You should already be familiar with how low you can go and the less fuel that’s in your tank before you start means the less mess you make when draining it. HM69 Fuel Tank Installation Instructions This manual is provided for marketing and informational purposes only and is a guide to assist experienced motorcycle technicians with the installation of the HM69 fuel tank. This installation involves gasoline. Improper installation, adjustment, alteration, service or maintenance regarding the HM69 fuel tank can cause property damage, personal injury or death. At-home Do-It-Yourself mechanics should not install the HM69 fuel tank if you are uncertain of your ability to properly install it and refer the installation to an authorized Ducati service department. ! REMOVE THE SEAT Remove the seat bolt at the rear of the seat with a 4mm hex key. To remove the seat, grasp both sides of the seat, lift the rear of the seat slightly, and pull the seat to the rear of the bike. The front of the seat engages onto bolts on either side of the fuel tank and can be stubborn. THIS KIT ALSO CONTAINS: © 2009 California Cycleworks, Inc. Questions? Email orders@ca-cycleworks.com 1
REMOVE THE BODYWORK The tank cover is fi rst. Remove the fuel fi ller cap and then the 4 screws you see: 2 near the front of the cover and the two aside the fi ller neck. Lift up on the forward portion of the cover and move the entire cover rearward so that the back of the cover is away from the retaining contour on the fuel tank. SIDE PANELS Remove the right side panel’s inner cover using a large coin. Both left and right side covers are retained by 3 screws with 4mm hex heads. Remove the 2 screws on the side of the tank (which were revealed with the removal of the seat). While holding the side covers to support them, remove the bottom screw. The left side cover pulls away naturally – take care not to drop the cover as the tool kit is housed inside of it, adding unexpected weight

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