FUEL TANK REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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Warning

•  Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

•  Fuel line spills and leakage are dangerous. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel gauge sender unit when removing or installing.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2.  Open the fuel-filler cap.

3.  Follow “BEFORE REPAIR PROCEDURE” before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE REPAIR PROCEDURE [MZR-CD (RF Turbo)].)

4.  Drain the fuel using the following procedure.

(1)  Disconnect the breather hose (when the fuel tank is full) or the joint hose (except when the fuel tank is full) from the fuel-filler pipe.

(2)  Drain the fuel by tilting the breather hose (when the fuel tank is full) or the joint hose (except when the fuel tank is full).

(3)  Siphon the fuel from the fuel tank using a fuel drawing pump.

5.  Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION.)

6.  Remove the service hole cover.

7.  Disconnect the fuel sender unit connector.

8.  Remove the tunnel member

9.  Remove the main silencer, presilencer.

10.  Remove the main silencer, presilencer insulator.

11.  Remove the rear under cover.

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Inspect all parts by performing “AFTER REPAIR PROCEDURE”. (See AFTER REPAIR PROCEDURE [MZR-CD (RF Turbo)].)

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1	Insulator
2	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
3	Joint hose (See Joint Hose Installation Note.)
4	Breather hose (See Breather Hose Installation Note.)
5	Strap
6	Fuel tank
7	Fuel-filler cap
8	Fuel-filler pipe (See Fuel-filler Pipe Removal Note.) (See Fuel-filler Pipe Installation Note.)
9	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Fuel-filler Pipe Removal Note

1.  Remove the rear tire (RH).

2.  Remove the rear mudguard (RH).

3.  Support the rear crossmember using a transmission jack.

4.  Remove the rear shock absorber lower bolts. (See REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)

5.  Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember 30 mm {1.2 in}. (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

6.  Remove the fuel-filler pipe.

Fuel-filler Pipe Installation Note

1.  Temporarily tighten bolt A. then tighten in the order of B, then A.

Breather Hose Installation Note

1.  Fit the breather hose onto the respective fittings, and install clamps as shown.

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Joint Hose Installation Note

1.  Fit the joint hose onto the respective fittings, and install clamps as shown.

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