2 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
 Parts catalogue
 Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the fuel tank
 
Unscrew and remove the fuel tank filler cap (4).
Unscrew the bolts (5) and (7) and remove the fuel tank cover (6), withdrawing it towards the seat.
Recover the washers (12).
Remove the bracket (G) by unscrewing the bolts (H).
Disconnect the turn signal and number plate light wiring connectors (A) (Sect. P 1, Routing of wiring on frame).
Withdraw the regulator fures assembly (B) from the support (C) and the self-diagnosis connector (E) from the strap (F) on the fuel tank.
Release the main wiring loom from the fuel tank (1) by opening the metal clips (D).
 Warning
Before removing the flange cover (20), check that the fuel tank (1) is empty.
 
Unscrew the nuts (21), remove the flange cover (20) and disconnect the quick-release fittings (13) from the flange.
Unscrew the bolts (M) securing the fuel hoses (N) to the fuel tank.
 Warning
Unscrew the special bolt (L) while counterholding with a size 5 Allen key the threaded insert located on the top of the tank.
Remove the fuel tank (1) from the motorcycle.
Removal of the fuel tank filler cap
Remove the hose (2) from the breather valve (3).
Release the breather valve (3) by turnig it anti-clockwiseand remove it from the fuel filler (8).
Remove the fuel filler flange (8) by unscrewing the bolts (10) and recover the O-ring (9).
Refitting the fuel tank filler cap
Fit a new O-ring (9).
Refit the fuel filler flange assembly (8) in its housing in the tank and tighten the bolts (10) to their specified torque (Sect. C 3, Frame torque settings) in the sequence 1-2-3-4-5-6-7.
Fit a new O-ring (33) on breather valve (3).
Insert the breather valve (3) in its seating on the fuel filler flange (8), applying the recommended lubricant to the surface in contact with the flange to facilitate assembly. Turn the the vlave clockwise to secure in place.
Fit the hose (2).
Removal of the fuel tank flange
Unscrew the bolts (19) and (22) securing the fuel tank flange (11).
Remove the flange (11) from the fuel tank.
Recover the O-ring (30).
Using the appropriate tool, undo the clips (15) next to the fuel filter (14).
Remove the old filter from the connecting hoses and fit a new filter.
Before reassembly, carefully remove any deposits or scale from all parts.
 Important
When installing the new filter, position it so that the arrow stamped on the outer casing points towards the flange.
 Notes
The flange is supplied as a spare part complete with the fuel pump and pressure regulator: the entire flange assembly must be replaced in the event of malfunction.
Refitting the fuel tank flange
Grease the O-ring (30) and locate the flange and refit by reversing the steps of the removal procedure.
Tighten the bolts (19) and (22) to the specified torque (Sect. C 3, Frame torque settings), in the sequence 1 -2 -3 -4 -5 -6.
Locate the flange wiring, securing it as shown.
Refitting the fuel tank
If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the figure. In particular: tighten the bolts (26), (28) and (A) to the specified torque (Sect. C 3, Frame torque settings).
 
If the battery retaining plate (34) was removed, refit positioning it as shown; insert the bolts (35) and tighten them to the specified torque (Sect. C 3, Frame torque settings).
Fit the battery retaining plate (32), positioning it as shown; insert the bolts (24) and tighten them to the specified torque (Sect. C 3, Frame torque settings).
Reposition the fuel tank (1), engaging the front and central catches on the rubber bushes located on the frame.
Locate the fuel hoses (N) on the tank and tighten the bolts (M).
Connect the quick-release fasteners (13) o the flange, refit the flange cover (20) and tighten the nuts (21) to the specifie torque (Sect. C 3, Frame torque settings).
Secure the main wiring loom to the fuel tank (1) by closing the metal clips (D).
Disconnect the turn signal and number plate light wiring connectors (A) (Sect. P 1, Routing of wiring on frame).
Reposition the regulator fures assembly (B) on the support (C) and the self-diagnosis connector (E) by closing the strap (F) on the fuel tank.
 Warning
Screw in the special bolt (L) while counterholding with a size 5 Allen key the threaded insert located on the top of the tank.
Refit the bracket (G), apply the recommended threadlocker and tighten the bolts (H) to the specified torque (Sect. C 3, Frame torque settings).
Fit the cover (6) by first inserting the tab (M) in the recess (N) on the tank and then locating the cover on the tank.
Fix the tank cover (6) with bolts (5) and (7) and washers (12).
Tighten the bolts (5) and (7) to the specified torque (Sect. C 3, Frame torque settings).
Screw on the fuel filler cap (4).
 
Positioning of the fuel tank breather and drain hoses
Positioning of the fuel hoses