Revision as of 03:17, 12 June 2008

How to Remove the Gas Tank

1. Remove front seat. Use your key.
2. Remove rubber caps from the fuel shut off valves. Run screws in all the way to shut fuel off.
3. Remove speedo dash – 3 qty # 5mm Allen. Unplug all connectors including the small white one. Note order of plugs then un-snap from brackets on tank. Disconnect vent line.
4. Left Side Cover – remove secure style tamper proof torque bolt. (Special tool needed.) Then remove bolt on the side cover at front under frame. The side cover will not come off but will move enough to allow fuel lines to be disconnected.
5. Un-snap plastic clamps holding fuel shut off valves.
6. Pivot valve down to aid in disconnection. Then pull out the side & leave hanging. Will stay attached to tank. Disconnect upper valve at lower hose – has squeeze type hose clamp – will remain attach to tank also.
7. To remove fuel tank. Remove decorative fins at the front of tank. 2 allens #4 on each side.
8. Remove two 10mm nuts at rear bracket holding tank.
9. Remove 2 qty 12mm bolts at the front bracket holding tank.
10. Remove gas tank – lift straight up and off.

Reference: http://forums.delphiforums.com/starroadliner/messages?msg=8130.2

Shortcut Method

1. You can also swing the tank around and set it on the frame, or on a chair, without disconnecting the fuel lines. Remember to protect the frame and tank with a towel.
2. NOTE: At least 1 person has reported that the soft fuel lines can start leaking after using this method multiple times. If you smell gas, it may be time to replace the stock fuel lines with a higher grade automotive gas line (7/16").

Reference: http://forums.delphiforums.com/starroadliner/messages?msg=9328.1