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Installing a new Fuel Tank

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8.7K views 36 replies 10 participants last post by  dave97402  
#1 ·
My bike was backed into recently by my gf's aunt... No serious damage, just broke the bar end mirror, bent the handlebar, and dented the tank. All new parts were ordered at their expense so I cant complain too much.

Question is, getting the tank itself off seems relatively straight forward, but do we have an in tank fuel pump and a fuel level sensor? How easy is that to remove and place in the new tank?

2013 650. Almost forgot to add that... lol.
 
#6 ·
Its easy. I have the pdf along with some other ones that also describe taking the tank off (snorkel mod). PM me if you need them. If you just need reaussurance then yes it is a very easy process. I believe you might have to use a really long allen in one of the steps. I actually had to go buy some as the ones in the garage were too short.
 
#9 ·
I just replaced my fuel pump. It's very easy to do. Remove old tank off the bike. Drain gas. Remove 5 bolts for fuel pump and remove fuel pump. The o-ring should be still good. If you have a new one on hand use it. If not just re-use the old one.
Honestly the hardest part was reconnecting the hoses to the EVAP can
 
#11 ·
Allen socket set. You then have access to any extensions and/or elbows you may already have.
 
#12 ·
Great. Dealership called and my new tank is in. :) Will pick it up and install tommorrow. Maybe do a quick tutorial. It seems easy enough. Thanks guys for the manuals and advice. I will let you know how it goes. Will also post pics of the damage. It's not too bad, will be a good surface to practice my airbrushing on.
 
#16 · (Edited)
I feel like the stock fork legs are so thin on a bike like this, especially with the fairings not covering the uppers. And I thought my old 500 had some thin looking fors lol. Those things are 47mm vs the 41 on the 650.

EDIT: MEant to say/type 37mm.
 
#18 ·
Lean It
That Puig windscreen looks awesome. Not sure where it mounts or how it would fit over my headlight assembly. Plan to eventually build a dual projector vertical headlight that this would look great over.

Blue Sentra
Thanks, with the crash bars the bike will look great. No price yet from the Thai shop though. May have to fabricate something.
 
#19 ·
You did see this ER6N Streetfighter pic right? With dual headlights.
Image


I'm pretty sure it mounts to the forks.
Image

PM thesleeper and ask how it mounts up.
 
#21 ·
Pretty sure it's a Ducatti 1098 tail, there's actually a thread on here on how to do it if you are ambitious! http://www.riderforums.com/general-ninja-650r/76363-ducati-1098-tail-swap-10.html
The vertical headlights are awesome if they are projectors IMO.

Check out these site for some headlights and other stuff, they specialize in Streetfighters:

Wild Hair Accessories

Moto Madness Streetfighters

I love streetfighters, I will build one someday even if when finished, I just park it in my living room to look at. BTW, parking your bike in your living room is great when your a bachelor, but only if your on the first floor! Lol
 
#24 ·
Howdy,

My son got a 2013 Ninja 650 last year. Got a great deal and a sweet bike! This winter he is going through and doing maint service and such. We ran into a issue where we are trying to get the tank off. It is the style I believe like your nevyn04 with the ignition in the tank, or at least that is the way it looks. I can't seem to find any pics or anything that explains how to take it off.....we have the main info for removing hoses connectors and such....we just don't want to force something that isn't suppose to be forced.

Can anyone point me in the right direction??

Thanks in advance
 
#26 ·
Yeah I have looked through that. The tank we have has the ignition in the front of the tank, (or at least bracketed in their) with a front black cowl piece that is not shown in any manual I can find. Seems to be hung up right at where the ignition switch is??
 
#27 ·
That's the manual for 06-08. You need the one for 12+. I know it's out there and has been mentioned frequently.

06-08 has the ignition switch attached to the upper triple tree so it isn't a consideration when removing the tank.
 
#29 ·
You need to remove the bolts holding the plastic on the tank. They are forward and to the left and right of the tank. Remove your seat and unbolt a few more bolts. You then have to unplug your fuel line. I am sure this is in tr manual and if the part about the plastics isn't mentioned then just add that part. I can explain better when I get home to a real computer if someone doesn't help you first.
 
#30 ·
Also, I have a pdf of how to do this for maintenance and some modding. If you would like that along with a 2013 service manual, pm me your gmail and I will share it via Google drive. There are a few other goodies in there as well.
 
#32 ·
Dave the guide I shared and the reply I wrote are both correct. The ignition is not really built into the tank but only looks like it. Once you pull that plastic piece off you will know what I mean. Take the plastic off, unbolt the bolts up front, unbolt the rear tank bolts under the seat, unclip and unplug the tank from the left hand side ( left if you were sitting on the bike) and the tank lifts off, leaving the ignition on the bike.
 
#33 ·
Were you able to figure it out?