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Thread: HEXHEAD Tech - R1200RT - Gas Tank Removal - 2008 Model

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    HEXHEAD Tech - R1200RT - Gas Tank Removal - 2008 Model

    The articles, posts and comments in this tech section are posted by individual members and reflect their personal thoughts and experiences with repairing, maintaining, and generally working on motorcycles. This information may require specific knowledge and skills, may or may not be correct or current to model.

    The authors of information found here and the BMW MOA take no responsibility for ensuring the accuracy of any information (including procedures, techniques, parts numbers, torque values, tool usage, etc.), or further for any damage of any kind or injuries incurred or caused by anyone following the instructions or information found here.

    It is the duty of the individual to either assume the liability himself for responsibly using the information found here, or to take the bike or accessory to a Dealer or other qualified professional service.


    Lastly, please ensure you dispose of your used chemicals, oils and fuels in an environmentally responsible manner. Most Auto Parts stores and service stations will accept used oil and lubricants, tires and batteries, please check for your local availability.


    This article, text and photos are Copyright of the individual authors and the BMW MOA, any copying or redistributing is permitted only by prior written authorization.

    Apply all safety rules when handling volatile liquids

    Specifics:
    space- Bike shown is a 2008 R1200RT
    space- Heated Seats
    space- No Factory Radio

    Tools Needed:
    space- 5mm Hex Socket
    space- T-25 Torx Socket
    space- Small Straight Blade Screwdriver

    Space ÔÇô you will need a bit of space to stow away the panels and tank as they are removed 10ÔÇÖ x 6ÔÇÖ is minimal

    Recommendation ÔÇô Not required, but, it is easier to remove the tank the emptier it is,
    can be done full but remember there will be 7+ gallons of fuel.

    Process Steps:
    space- 1 All appropriate plastic panels removed
    Please refer to http://www.bmwmoa.org/forum/showthread.php?t=35262 for how to do this
    space- 2 Remove Center Trim Screw
    space- 3 Disconnect Electrical Connections to Fuel Pump
    space- 4 Disconnect Fuel Lines (2)
    space- 5 Disconnect Vent Lines (2)
    space- 6 Remove Tank Mounting Hardware
    space- 7 Remove Tank
    Last edited by Semper_Fi; 09-29-2009 at 02:28 PM.
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  2. #2
    Honey Badger Semper_Fi's Avatar
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    Once you have both sides of the bike plastic removed you can start working on removing the tank.

    First off, you need to remove the center trim screw, this is a T-25
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    Honey Badger Semper_Fi's Avatar
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    Looking at the Clutch side of the tank you will see where the fuel/vent lines, electrical connections and harness which need to be removed.

    In blue highlight you had the fuel lines, in green highlight is shown the electrical connections and in orange is the vent line.

    To the left hand side is the wire harness that needs to be removed.
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    There are 2 electrical connectors, one with 3 wires and one with 4.

    Remove the 3 wire as shown below.

    CAREFULLY open up the lock feature of the connector mount and remove the 3 wire connector.

    I am using a small straight slot screwdriver and just barely opening up the lock feature
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    Do the same for the 4 conductor connector
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    Honey Badger Semper_Fi's Avatar
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    Once the connectors are removed you can remove the wire harness from its capture points along the tank

    If you note the construction of the clip you will see two sets of serrated "teeth" which are the locking features.

    If you take your trusty small blade screwdriver and CAREFULLY Twist in a clock wise manner you will disengage the teeth

    Below is the detail of the lock feature - the next picture is unlocking

    NOTE - the red and green wrapped wiring is NOT OEM - it is owner installed.
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    Twisting to open.

    Once the harness is freed lay out of the way.

    Next are the fuel lines
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    Press down on this silver tab (highlighted in green)

    The process is while pressing down on the tab hold the bottom fuel line on the tank head and pull on the top of the line and will disconnect.

    Note - there may be a small amount of gas spilled

    The next two pictures will show the removal
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  9. #9
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    Pressing the tab and holding the bottom of the fuel line
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  10. #10
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    Line disconnects.

    Note again a small amount of gas will spill.

    Simalar process is now done to the other fuel line.
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  11. #11
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    The other quick release is the same as the previous.

    1 - press tab in (highlighted)
    2 - pull connection up

    Note - minimal gas spill will occur
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  12. #12
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    Push in tab
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  13. #13
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    Pull out connector

    Note - minor gas spill

    Last item to remove off of the tank control unit is the vent line.
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  14. #14
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    Carefully pry up on the vent line and lay out of the way
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  15. #15
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    Vent removed
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