Danger !!! Fire Hazard, possibility of leaking gasoline, fire, or
explosion.
Extinguish all flames or remove all ignition sources
before you begin. Do not attempt these procedures unless you
follow proper safety procedures for handling flammable liquids.
6
Fig 1. Remove side panels. Remove knee covers #1 and side
panel #4 by releasing the quick release fasteners #3. On the
Adventure, there’s one screw at the back of the tank, and one
screw under the tank as shown in these arrows.
Fig 2. Remove protective cap #1. Remove quick release fuel line
by pinching clamp #3. Remove electrical connections #4.
Fig 3. On right side of tank, remove quick release fuel hose #5.
Remove vent lines #6. Mark them carefully so you don't mix them
up. One line has white markings. On the Adventure these fitting
are on the top-left of the gas tank.
Fig 4. On the right side, remove Bolt #1 and bracket #2.
Fig. 5. Remove two screws holding upper gas tank body panel to
front gas tank cowling panel, as shown with the black arrow.
There's one screw on each side at the top of the tank. On the left
side of the tank remove bolt #4. The front of the tank is held by a
rubber bushing #9, do not remove this bolt. The entire tank
assembly, along with the upper tank panels can be removed from
the frame by gently pulling rearward and upward #8. Set the tank
carefully on the ground.
Fig 6. Once the tank is removed you can route the wiring harness
for your lights. To mount a Piaa relay we used zip ties and Velcro
and mounted it directly below the VIN plate, as indicated by #4. To
mount an IPF relay we used the screw on the left side of the
steering head, just in front of the VIN plate as indicated by #5.
When your work is complete, reverse the above steps to reinstall
the gas tank and body panels.
Piaa relay
IPF relay
