FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2]

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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.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION [4SD].)

5.  Siphon the fuel from the fuel tank.

6.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

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1	Fuel tank strap (See Fuel Tank Removal Note.)
2	Fuel tank (See Fuel Tank Removal Note.)
3	Joint hose (See Joint Hose Installation Note.)
4	Breather hose (See Breather Hose Installation Note.)
5	Insulator (See Rivet Removal Note.)
6	Fuel-filler cap
7	Dust cover
8	Fuel-filler pipe (See Fuel-filler Pipe Removal Note.)
9	Nonreturn valve

Fuel Tank Removal Note

1.  Remove the fuel gauge sender unit from the fuel tank. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)

Rivet Removal Note

Caution

•  Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

Note

•  The insulator is installed using rivets.

•  When reinstalling the rivet, install the same rivet or M5 bolt and nut.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel-filler Pipe Removal Note

1.  Remove the rear tire (LH). (WGN)

2.  Remove the fuel-filler pipe.

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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