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Griso 8V: How to remove fuel tank ?

ett

ett

Cruisin' Guzzisti
GT Contributor
Joined
Dec 31, 2011
Messages
161
Location
Allentown, PA
In order to change the alternator belt on my 2010 Griso 8V.
I've been trying to remove the fuel tank for the past hour.
The service manual has been completely useless. It simply states "remove tank"; but does not say how to remove it. :devil:

I've removed the side wings, seat, battery, battery tray, battery tray vent hose, one small tank vent hose located on the left side underneath, and the front tank bolts.

I am unable to raise the tank to remove any other hoses attached to tank.
Attempting to raise the fuel tank from the front results in the tank hitting the handlebar mounts.
And attempting to raise the tank from the rear results in resistance from the hoses that are still attached; but not accessible.

So just how the hell do you remove this damn fuel tank ??
 
The rear vent lines can be removed with some needle long nose pliers from under the frame rails with the tank in place. The only other frustration is the fuel line disconnect. Well covered here in a search.
 
Thanks Todd,

I did do a search. I was going by this thread:

https://www.guzzitech.com/forums/threads/tank-removal-on-griso-8v.4046/

It turns out that one of the vent lines was clamped onto the fuel tank, was zip tied to the main wiring harness, and has absolutely no excess play in that hose.
It's the hose for the EPA charcoal canister.

I had to break the clamp on that hose down by the (tip over ?) valve and cut the zip tie on the main wiring harness.
I was not able to disconnect the fuel line from the fuel pump.
So I simply propped up the fuel tank with a block of wood while I changed the alternator belt.

I am now putting everything back together.
But now I'm encountering the fuel tank not fitting back into place.
The bolts by the ignition key are not lining up.
It's as if the fuel tank has stretched by 1/4".
 
Ok. I just finished.
So that means it took me 7 hours. :(
A lot of that was due to many of the bolts not being easily accessible.
Many of them I had to use a small hex key. And turning the bolt 1/4 turn at a time. Fumbling with the hex key between each 1/4 turn.
And I spent at least 3 hours struggling with removing and reinstalling the fuel tank.
The trick was to install the front bolts before the back bolts under the seat that hold the battery tray.

The last hour of was getting the battery back in.
The battery cables have no excess play in them. So you can't raise the battery to a stable position when you want to connect or disconnect the terminals.
And when installing the battery; the battery always wants to crumple the rubber battery box. It never wants to slide inside of it.
So It takes a dozen or more attempts to install correctly.

If I recall correctly. I had to remove:
  1. Side body panels (air ducts ? wings ?).
  2. Fuel tank. (break clamp on EPA/charcoal canister at tip-over valve, remove 1 vent hose, disconnect fuel pump electrical connector.) And only partially removed. Propped up at front.
  3. Battery.
  4. Battery box.
  5. Horn.
  6. ECU.
  7. Right side coil.
  8. Alternator cover. (Three different type and size of bolts.)
  9. Large left side alternator mounting bolt and nut. (Nut is a very odd size. 15mm?)
  10. Loosen right side alternator mounting bolt and adjusting bolt.
I hope it was worth it.
Because although the manual states to change the alternator belt every 30k miles and my Griso has 77k miles.
The original belt did not look that bad. It was surprisingly clean and there were maybe 1/2 dozen cracks that only ran the width of a rib on the belt.

Any way; hope I got the belt tension correct and tightened all the bolts enough.
Some of the bolts; I could not tighten with a wrench on both bolt and it's nut.

Time to go for a ride. ;)
 
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