Fuel Tank Disassembly and Reassembly

DISASSEMBLY

1. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY




a. Remove the fuel tank main tube from the fuel tube clamp and tank suction tube support.

2. REMOVE FUEL TANK VENT HOSE




a. Remove the hose from the hose clamp.
b. Pinch the tab of the retainer of the hose connector to remove the lock claws and slide it as shown in the illustration.
c. Pull the fuel tank vent hose out of the pipe.

NOTE:
- Remove any dirt and foreign objects on the hose connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the hose connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
- If the hose connector and pipe are stuck, push and pull to release them.

3. REMOVE NO. 3 FLOOR WIRE




a. Remove the 3 wire harness clamps and floor wire.




b. Remove the wire harness clamp.
c. Separate the 2 claws fittings, then remove the fuel tank protector plate.

4. REMOVE TANK SUCTION TUBE SUPPORT




a. Separate the clip fittings, then remove the tank suction tube support.

5. REMOVE NO. 3 FUEL TUBE CLAMP




a. Separate the 2 clips fittings, then remove the fuel tube clamp.

6. REMOVE NO. 4 FUEL TUBE CLAMP




a. Remove the bolt and fuel tube clamp.

7. REMOVE NO. 1 FUEL TANK CUSHION




a. Remove the 10 fuel tank cushions from the fuel tank.

REASSEMBLY

1. INSTALL NO. 1 FUEL TANK CUSHION




a. Install 10 new fuel tank cushions onto the fuel tank as shown in the illustration.

2. INSTALL NO. 4 FUEL TUBE CLAMP




a. Install the fuel tube clamp with the bolt.

Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)

3. INSTALL NO. 3 FUEL TUBE CLAMP




a. Align the clip positions, then install the fuel tube clamp.

4. INSTALL TANK SUCTION TUBE SUPPORT




a. Align the clip position, then install the tank suction tube support.

5. INSTALL NO. 3 FLOOR WIRE




a. Align the claws positions, then install the fuel tank protector plate.
b. Install the wire harness clamp.




c. Install the floor wire with the 3 wire harness clamps.

6. INSTALL FUEL TANK VENT HOSE




a. Align the hose connector with the pipe, then push in the hose connector until it comes into contact with the seat to connect the fuel tank vent hose to the pipe. Then push the retainer up until to the claws lock.

b. Install the hose into the hose clamp.

NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the hose connector and pipe.

7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY




a. Fit the fuel tank main tube into the fuel tube clamp and tank suction tube support.