Gen2 Gas Tank Removal

[Foreverblue]

Thank you Foreverblue - I can't fit the cable between the tank and the frame though - no space. I'm thinking of just doing a long run over the back fender down and around. How did you get the cable to fit?

Can you fit though this part??



Do you have pictures in that area? also the side picture.

Also you are not that far away from me.

 

[deathpulse]

Hey Forever - thanks a ton for your help on this! BTW - I moved from the Jerz down to Virginia a few years ago but just realized I haven't updated my profile to reflect that :/. I have a few pix attached that show how tight the fit is. I don't seem to have room in the space you have marked out, unless I somehow find a "thinner" cable. Its also a super tight fit against the gas line and the computer. I tried to post a few pics to show overall fitment.

 

[Foreverblue]

Hmm... Your gas tank sits about half inch further up than my tank.



Anyway, this is how I route my cable. It's tight. It's ok to pinch it as long as the cable in the middle is free moving.

 

[deathpulse]

Huh - did you relocate the "black box" electronic box that sits on the rear fender? My tank runs right up to it....

 

[Foreverblue]

Yes I did. That thing is still in the same location, move back one screw hole and only tie down with one screw.
Also your rear fender and the under liner might not married correctly when you put it back.

 

[deathpulse]

OK, I got the seat cable routed in without moving the "black box" back... everything fits but VERY tight. Aaaand I just realized I need to put the electronic mounting thing on the right rear side . I'll pull the plastics off the bottom and try and get the electronic mount (the thing that the EXUP attaches to) on. Once I have that completed, I think its just bolting everything back up!

 

[deathpulse]

ALMOST finished! Everything is back and working (the seat cable worked much smoother once I bolted the frame to 30 ft lbs each).

BUT - I can't get the front seat on! The seat is hitting the fuel tank things I highlighted in the attached picture. How did everyone deal with this? Did you dremel out some of the seat plastic/can you show me pictures of what you took out? Thanks in advance!

 

[ShawnD]

ALMOST finished! Everything is back and working (the seat cable worked much smoother once I bolted the frame to 30 ft lbs each).

BUT - I can't get the front seat on! The seat is hitting the fuel tank things I highlighted in the attached picture. How did everyone deal with this? Did you dremel out some of the seat plastic/can you show me pictures of what you took out? Thanks in advance!

Can you take a shot from the side or measure how high those two fittings sit above that frame bracket? Seems like that would be something that should have been mentioned in the instructions. This is where those fittings are on mine.

 

[ShawnD]

 

[deathpulse]

Wow, your tank is quite a bit lower in than mine. Is that the larger of the two? I have the 24.5 liter tank from this site: Schwabenmax Motorcycle Parts. Motorcycle accessories and motorcycle tuning in premium quality. Specializing in motorcycle tuning and refinement for Vmax, K1200R and K1300R as well as the GSX 1400.Specializes on gas path shortening on motorcycles. | Detailed view | Tank | Tank for Vmax 1700. 24,5 Liter

I'm not sure why mine is so high? Here are two pictures of the high mine sits at:

 

[deathpulse]

Forever, did you have to mod your stock seat?

 

[deathpulse]

Update for the group - I think it was partly seat fitment with the cross frame member that the seat "plugs into" and a bit of spacing on the fuel pump stuff. I grease penciled the fuel pump stuff and put the seat on to figure out where it was slightly hitting then dremelled those areas down a bit. I also screwed around with the front cross member fitment and finally got it all together!

phew.

 

[Foreverblue]

Sorry for the late reply. Here is my tank. I relocated the 2 wires to the side. I didnt modify my seat.

 

[ShawnD]

That small rectangular recess in the center is where those fittings sit...it might just be enough to clear but it looks like it would be tight. Don't know about anybody else but I've always had a bit of difficulty getting the seat lined up in the front...have to play with it a bit to get those front tabs on each side to slide into place. The bolts wouldn't line up if I didn't get it right the first time.

 

[deathpulse]

Thats a REALLY good point Sean. I didn't carve out that whole rectangle (area that says P P 2S3-00S) but that might actually be the best way to do it. Also the "lip" below the rectangle area - I may cut that out too. That should reduce the risk of smashing the pump fittings and really shouldn't hurt the seat at all. Thought?

 

[ShawnD]

Thats a REALLY good point Sean. I didn't carve out that whole rectangle (area that says P P 2S3-00S) but that might actually be the best way to do it. Also the "lip" below the rectangle area - I may cut that out too. That should reduce the risk of smashing the pump fittings and really shouldn't hurt the seat at all. Thought?

I don't think it would hurt the seat but I'd press down on the top of the seat to be absolutely sure the foam doesn't push through...I'd want to be absolutely sure nothing contacted those fittings.

 

[deathpulse]

Here are some pictures of the finished product. She seems to run great with no leaks but the tail fitment isn't great. Its an ok compromise for 24.5 liters of go juice though .

 

[deathpulse]

Did any of you guys clean the inside of the tank before you installed it? I wiped down the bottom surfaces with a rag and some brake cleaner but didn't wipe down the sides or the top. I didn't go crazy with it.

 

[Akbash]

Just got back from checking out my friends 2020 install of the swab 24.5 litre tank. It took some time but he got his rear fender liner to fit 99% perfect no cutting no modding. Also used stock bracket for rear brake fluid and stock fuel tank breather hose. One of the keys to fitting it to frame was how you shaved down those rubber pads. He was able to get tank far enough forward to fit the fender liner no problem. His seat fits no problem with out mods. He did mention he had too grind a tiny bit of weld that was keeping the tank going forward it was the weld under the main seat support left hand side. Weld was hitting frame seat support so it would not move forward enough. Made sure the brake lines were pushed too the side so tank would fit farther up. Also said if he wanted it to fit 100% he would slightly smooth out the welds under the plastic liner so it would fit 100%

 

[Akbash]