how hard to replace a tank

[sunshine]

gday
im just thinking about replacing my tank on a 1990 zzr
thats if i can pick one up in better nick than mine

as its had more hits than elvis

and as im not well versed in motorcylcr repairs and
dont have any specific tools either

i would love to know from some of the brainstrust
that frequent the site

should this be farmed out or could i attempt this with some efffort ???
and if i farmed it out approx cost
.
appreaciate all replys cheers mick

[Neka79]

hmm dunno wot a new tank b worth, prob more than its worth ..but u may find a 2nd hand tank from maybe $100 or so, depending on condition...
as ive only pulled a zzr250 apart, and dunno wot size ur bike is, i can say it took me abt 5 min to pull the tank off a zzr250...and my blade takes abt 3 min (has quick release race hose joiners on the fuel line).....
wouldnt b that hard to do a full swap...

[sunshine]

yeah thankx neka

ive just signed up with findapart for a tank in my colour scheme
so i hope something comes up in good nick
and at a resonable price

the bike is a 1990 zzr 600


will i need to take of the upper fairing off for this ???
and or need any specific tools

i realy need to get a manual im flying blind here

thanks for the reply

[Strika]

It's been a long time since I pulled on of these apart so my memory may be a little sketchy, but here goes.

Pull the seat off first.

There should be two bolts holding it in place at the rear (10mm from memory) and there should be the either two bolts vertical in the front or maybe one that mounts horizontally. I can't remember which but you will see them or it depending.

It helps if you loosen off the side covers (rear body work) it makes it easier to manoeuvre things.

From there it's a simple matter of unplugging all the hoses and electrics and swapping it all over. Then reverse process.

A mechanic would charge about $600 dollars but if ya want I will do it for ya on the cheap for say $550, cause yr a KSRC member . I'm not a mechanic, and have no idea, but after the 16th stubbie nobody cares!!!!

[Rusty]

They're pretty easy.

At the front there should be two 8mm bolts, and one 12(I think)mm at the rear. You'll need some screwdrivers, too.

1. Take the seat off.
2. Take out the screws from the front of the side covers. I also take out the next pair as well. This is to allow the side covers to move outwards to clear the tank.
3. Remove fuel hose/s.
4. Remove mounting bolts.
5. Remove tank. There may be an electrical plug, too, not sure on the early ones.

Total time: less than 10 min. It's a lot easier when the tank's pretty much empty.

*edit* Gonna have to read threads before replying to 'em ...

[Gosling1]

Changing tanks is a piece of piss mate.

Important things -

Don't lose any of the bolts when removing;

Do it with an empty tank;

Don't mix up the hoses underneath the tank if you have more than 1 of them (also sometimes 1 line is thinner than the other - don't mix 'em up);

Don't forget the electrical connection if fitted;

Just take care when taking the tank off, as Strika suggested, loosen some of the bodywork at the rear of the tank to help when taking tank off.

Also make sure the fuel tap on the replacement tank is a goer - test first if your not sure.

Good Luck - it really is a 5-minute job !!

[ZX10R King]

http://cgi.ebay.com.au/KAWASAKI-ZZR-250 ... dZViewItem


Check this out, don't know what colour ur after, or how much, but at least its there if ya want it

[sunshine]

hey thankx for the tips
all greatly appreacated

if i can get a good tank in my colour
ill be fitting it real ssooon

one other question if i could gentlemen

the bike as some stage has had a meeting with terra firma

and the bars have dented the tank on the left hand side

so it appears to have bent the bars fractionally
and now the bars always hit the tank

does this sound right ???

and does this now mean i need to replace the clip on handle bars

although the bike steering seems fine
sorry for the dumb questions


thankx mick

and strika when i get the tank ill supply the vbs and the cheque will be in da mail ha ha

[Neka79]

hmm sumtimes on sum bikes..the bars go bloody close to hitting the tank neway...
ud have to pull the clip-on off, and measure it to see if its bent...

from memory a new clip on for my cbr 929 was abt $200 ..thats a gen OEM one...i believe u can get cheaper sumwhere, u can also get 2nd handy, but u may be buying the same problem....

HTH

[mrmina]

not hard. about 4 bolts holding the thing on.

about 10 minutes with a couple of smoko's