2 - | Fuel tank

1 | Fuel tank

2 | Filler cap

3 | Screw

4 | Hose

5 | Union

6 | Hose

7 | Hose

8 | Rubber

9 | LH bracket

10 | Screw

11 | Rubber

12 | RH bracket

13 | Screw

14 | Washer

15 | Rubber

16 | Guide

17 | Screw

18 | Fuel outlet hose

19 | Fuel return hose

20 | Cover

21 | Nut

22 | Special screw

23 | Flange

24 | O-ring

25 | Filter

26 | Hose clamps

27 | Thermistor

28 | Screw

29 | Quick-release fitting

30 | Screw

31 | Washer

Parts catalogue

Fuel tank
Fuel System

Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the fuel tank
Remove the seat (Sect. E 3, Removal of the seat).
Remove the fuel tank covers (Sect. E 2, Removal of the fuel tank fairings).
Remove the breather hose cover (Sect. N 8, Removal of the alternator-side crankcase cover).
Withdraw the breather hose (6) from the cover (A).
Withdraw the hose (6) upwards, leaving it attached to the tank breather and drain hose unions.
Working on the right-hand side of the motorcycle, disconnect the wiring connector (B) of the fuel level sensor from the main wiring harness, unscrew the screw (30) securing the side of the tank to the frame and recover the washer (31).
Remove the screw (13) and recover the washer (14).
Release the fuel hoses (18) and (19) from the clips (16).
Detach the lambda sensor cable (C) from the tank flange cover.
Warning
Before removing the flange cover (20), make sure the tank (1) is empty and position a rag to collect any spilt fuel.
Raise the tank, remove the flange cover (20) by unscrewing the nuts (21) and disconnect the quick-release fittings (29) from the flange.
Removal of the fuel tank filler cap
To remove the fuel filler cap assembly from the fuel tank proceed as follows.
Remove the fuel tank covers (Sect. E 2, Removal of the fuel tank fairings).
Open the filler cap.
Unscrew the outer screws (3) securing the ring nut to the filler cap recess.
Remove hoses (4) and (7) from the filler cap assembly (2).
Remove the filler cap assembly (2).
Refitting the filler cap
Refitting is the reverse of removal.
Tighten the screws (3) to the specified torque (Sect. C 3, Frame torque settings).
Removal of the fuel tank flange
Unscrew the screws (28) and (22) securing the fuel tank flange (23).
Remove the flange (23) from the tank.
Recover the O-ring (24).
Using the appropriate commercial tool, undo the clips (26) next to the fuel filter (25).
Remove the old filter from the connecting hoses and fit a new filter.
Before reassembly, carefully remove any deposits or scale from all parts.
Important
When installing the filter (25), position it so that the arrow on the external housing is pointing towards the flange.
Notes
The flange is supplied as a spare part complete with the fuel pump and pressure regulator: the entire flange assembly must be replaced in the event of malfunction.
Refitting the fuel tank flange
Insert the flange (23) in its housing in the fuel tank.
Fit the four screws (28) and tighten to the specified torque (Sect. C 3, Frame torque settings).
Insert the two screws (22), positioning them so the ends with threadlocker are towards the flange and tighten them to the specified torque (Sect. C 3, Frame torque settings).
Refitting the fuel tank
If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the exploded view. In particular:
tighten the screws (10) and (17) to the specified torque (Sect. C 3, Frame torque settings).
Refit the fuel tank inserting the pins (D) of the mounting brackets (9) and (12) in the correponding locations in the frame.
While holding the tank in the raised position, connct the quick–release fittings (29) of the fuel outlet hose (18) and return hose (19) to the flange:
fit the fuel outlet hose (18), orienting it as shown in the figure, inserting the fitting (29) in its union in the flange (identified with the word “OUT”), until you feel a click;
fit the fuel return hose (19), orienting it as shown in the figure, inserting the fitting (29) in its union in the flange (identified with the word “IN”), until you feel a click;
Attach the fuel hoses (18) and (19) to the clips (16).
Refit the cover (20) fitting the two nuts (21) to the two screws (22) and tightening the nuts to the specified torque (Sect. C 3, Frame torque settings).
Connect the fuel sensor (B) to the main wiring harness.
Locate the lambda sensor wire (C) on the tank flange cover and secure it with a cable tie.
Fix the fuel tank to the subframe with the screw (13) and washer (14) and to the subframe with the screw (30) and washers (31).
Tighten the screws (13) and (30) to the specified torque (Sect. C 3, Frame torque settings).
Locate the fulr tank breather/drain hose (6) on the motorcycle and refit the breather hose cover (A) (Sect. N 8, Refitting the alternator-side crankcase cover).
Refit the fuel tank covers (Sect. E 2, Refittings the fuel tank fairings).
Positioning of the fuel tank breathe/drain hoses
Positions of the fuel hoses connecting the fuel tank to the throttle body