Ducati Monster Forum

Hey folks,

I have been trying to find info on how to remove the tank and fuel pump in order to ship my tank for repairs. If you know of where I can read this info please point it out, or if you have done it before, please debrief the steps to take and level of difficulty. Would I be better off taking it to the shop and have them do it and if so, how much would that cost based on a 70.00 hr rate? Anyone?  [thumbsup]

no point in taking it to someone. just ride the bike empty, put it on the rearstand if you have one, if not just get someone to hold hte tank up. disconnect the power line. and unplug the two hoses to the tank. i think they are premarked, but mark them anyway. then put the tank back down, there are threee bolts that hold the pin, you can either take that of, or knock the pin out. the later is easier. after that, turn your tank around, there will be a few bolts around a circular thing. thats your fuel pump. un bolt and the whole assembly comes out, that is the pump and filter. after that turn it back around and remove the 6 bolts that hold the gas cap (only 3 of them are real, the other are just there for symmetry).

and your done. shouldnt take more than 10 mins really. Also, when you turn the tank over to get to the pump, ou might spill gas out the cap, so i recommend you do it at an angle.

have fun

Hey ! that sounds pretty easy! I will use your steps..................... thanks man.. I mean He-man! ;)

 [thumbsup]

i forgot to mention, there are actually 3 or 4 tubes on your tank. the two big ones are teh fuel, the other are just vents.

also, its very likely that you might snap those plastic collars. they aren't ment to be reused, but you can if you are careful... some people just cut the black tube in the middle and use quick disconnects so you dont have to keep replacing those white things. they are something like 20 buckss for 2.

HeMan described the method for plastic tank Monsters....


Assuming your bike is a steel tank S4R from your avatar pic...

Tank removal

It'll be easiest if your tank is empty or nearly empty.
Siphon out as much fuel as possible, preferably with a squeeze-bulb siphon, available at boat shops.

Disengage the latch at the front of the tank.

Hinge the tank up.

Disconnect the electrical plug.

Disconnect the vent and drain hoses, they can be identified by where they route to, either straight down the back toward the bottom of the motor, or to the emissions canister.

Prepare some 'plugs', short sections of 5/16" fuel line with one end plugged with a bolt and hose clamp.

There are two fuel lines.
One is delivery, usually it will have a white plastic collar with an 'M' on it.
The other is return, usually it will have a white plastic collar with an 'R' on it.
Draw a picture, take a picture, or somehow record which hose goes where.

Remove one hose at a time, quickly using a plug to seal off the nipple on the tank.
*CAUTION* If there's any fuel in the tank, it will come out fast when you remove a fuel line.
Have several shop rags underneath the area before you pull the hose.
And no open flames nearby....

Remove the pivot pin at the rear of the tank.

Fuel Pump removal

Open the fuel filler cap.

Remove the three screws holding the cap on, they're at roughly 12, 4, and 7 O'Clock.
Remove the one that's inside the filler opening, at roughly 5 O'Clock.
The cap assembly can now come off.

Loosen the small setscrews around the rim of the filler plate, IIRC you'll need a 1.5mm allen wrench.
Back 'em all out a couple turns.
Don't take 'em all the way out.

Pull the filler plate out.
You may need to use a hammer handle or the like in the opening to get some leverage to pop it loose.

Disconnect the two hoses that are attached to the filler plate.
Draw a picture, take a picture, or somehow record which hose goes where.

Now you can see the fuel filter and hoses.
Unhook the fuel line that is connected to the metal tube in the tank that's at about 2 O'clock in the opening.
Pull the fuel filter out of it's clip.

Reach down inside, and pull the fuel pump out of it's clip.

Carefully maneuver the fuel pump out, there's a big flat mesh filter/strainer on the end of it, don't rip it on the clips.

Unplug the wires connected to the fuel pump.

Remove the big nut holding the fuel level sender.
Pull the sender out, use care to not damage the wires.

wow good eye speeddog! i thought it was an S2R 800!

1) that "how to" should be in the HOW TO section.....very good!
2) if you are going to ship the tank, make sure it is completely dry of fuel, and fumes have all vented. set it out in the sun and let evaporation do its thing. there are some types of purging fluids you can use if you are really anal, but not really necessary.