1500 Fuel Tank removal Aaaaaaaaaaaaaaaargh

[Sidcar]

I'm trying to remove the fuel tank on my '91 GL1500, it's badly rusted inside and I've got a good one off Ebay to replace it. I've followed the manual and removed saddlebags, trunk, rear mudguard, assorted pipes and electrical boxes, silencers plus rear shock absorbers, battery box but the tank comes out so far then fouls the rear hub. To me it looks like the rear hub and the starter motor are going to have to go as well. I tried to take the collector box off to get the swinging arm lower but the clamp bolts are seized and, thanks to the tank just above, I can't apply heat like I normally would.
Any information gratefully received.

Sid

[Sidcar]

I've now taken the hub off but still it wont come out. There's now more of the bike on the floor than attached to the frame.

Sid

[Mag]

...........There's now more of the bike on the floor than attached to the frame.

Sid

Don't you hate that? That is what I am afraid of, finding that I have more on the floor than I expected or wanted. Fingers crossed!!!!

[Bamaeagle]

I have not had to remove a fuel tank from a 1500.....but I did some search on another forum and this is what a member there had to do to get his out from a 94-95 1500.......

"I got the tank out after removing the final driven gear housing and some light coaxing with a rubber mallet. Hardly any dings/damage to the tank other than a few light scratches. I don't care what the manual says I don't see how the tank can be removed without removing the final driven gear with out beating the crap out of the tank. In short my remedy to remove the tank is as follows:


1. Remove the rear wheel, rear fender and final driven gear housing.
2. remove the relay box on the left side of the bike
3. remove the battery and battery box.
4. remove all fuel hoses, spill tray, etc.
5. be careful not to pinch/damage any wires. Move any wires out of the way. You will have to remove some of them from thier retaining clips.


With a rubber mallet or dead blow hammer gently tap on the tank to get it out. The tank comes out from the rear of the bike between the swing arms.

Hope this helps future members looking to remove their tank.

In all took me about 2 hours."


Good Luck on getting yours out and be sure to let us know how you did it.

Ride Safe Always!

[Sidcar]

Don't think I haven't been tempted to use some force (7lb sledge never mind a rubber mallet) but it ain't going to get this tank out.
The big problem at the moment is domestic life and work are seriously erroding the time I can devote to the Wing.
However, unless someone has a better idea, the plan is to remove the starter, the collector box and the swinging arm, in that order until the b****y thing comes out.

Sid

[bustedwing]

Well, if I was closer I'd pop on over and give you a hand but there is a little pond between us so I guess that's out.There has to be something holding it in, hell you have damn near everything off the frame it should fall off pretty soon.

[Sidcar]

Did anyone hear a distant cry of "Hoo-b****y-ray" at about 9.20 am BST? That was the moment I finally got the old tank out. I removed the collector box and heat shield (which mean't removing the r/h exhaust front pipe first I could then work the collector box off the l/h ex pipe. I couldn't drop the pipes and box down in one unit because of the sidecar fittings!). This allowed the swinging arm to drop that little bit extra. The tank almost, but not quite, slid out. I had to remove the starter to get that final half inch of clearance allowing the tank, with a firm push, to slide out. On the positive side I now have plenty of room the service the rear master cylinder and the rear caliper.
One final question "How the hell does it go back together?"!


Sid

[bustedwing]

Well, look at it this way, you are half done.

[redial]

Nothing is wasted - what a great learning experience. It should be just about assembled in time for Winter

However, I am glad that you were able to do the extraction, even with the complication of the sidecar mountings running interference on your project.

[Blackngold]

HOLY CRAP! With my limited abilities I'd part it out on E-bay,take the cash and buy another one this time w/no rust! Why is it easier to take something apart than put it together?

[Sidcar]

I've got the "new" tank in and connected and I just refitted my overhauled master cyinder so now it's just a straight forward rebuild.......If only I knew where this bolt went and I don't even remember taking that bracket off.
Anyone good a jigsaws?

Sid

Some day I'll look back on this an laugh

[bustedwing]

I know it is an after thought, but a camera woud have been a good tool while you were going thru the tear down steps. It's amazing what we forget in a short time.At least you will know every nook and cranny on that bike.

[Kiwi2]

I bet the wife and kids stayed clear while you were trying to get the tank out ........ enough language to make a trooper blush.

[ydeardorff]

I learned a long time ago to put the screws nuts and bolts back into the parts they came out of. Keeps everything straight and you dont lose parts.
I just admitted to the fact I will have to pull my tank as well and por15 it....
Not looking forward to its. But in the end it will be piece of mind that its been done.

[AZgl1800]

I learned a long time ago to put the screws nuts and bolts back into the parts they came out of. Keeps everything straight and you dont lose parts.
I just admitted to the fact I will have to pull my tank as well and por15 it....
Not looking forward to its. But in the end it will be piece of mind that its been done.

IMO,
POR15 is bad news.

Use electrolysis instead, that will remove every speck of rust from the tank, and the fuel level sensor.

[Sidcar]

My second hand tank off eBay was like new inside and cost me about £45, much better than treating a rusty tank.
Best of luck

Sid.

[DarthJ]

I learned a long time ago to put the screws nuts and bolts back into the parts they came out of. Keeps everything straight and you dont lose parts.
I just admitted to the fact I will have to pull my tank as well and por15 it....
Not looking forward to its. But in the end it will be piece of mind that its been done.

I ended up calling a welder to cut one side of the bracket that the rear of the tank bolts to. Made it so much easier and only cost me $50. you could cut one side, deal with the tank, then call someone (or do it yourself if you have the equipment and skill)