Fuel tank

2 -

1

2	Filler cap

3

4

5

6	Breather hose

7

8	Rubber pad

9	LH bracket

10	Banjo bolt

11	Rubber pad

12	RH bracket

13	Banjo bolt

14

15	Rubber pad

16

17

18	Fuel outlet hose

19	Fuel return hose

20

21

22	Banjo bolt

23

24

25	Fuel filter

26	Clamps set

27	Thermistor

28

29	Quick-release fitting

30

31

32	Sealing washer

33

34	Heat shield

Spare parts catalogue


1100 ABS	Fuel tank
1100 ABS	Fuel System
1100 S ABS	Fuel tank
1100 S ABS	Fuel System

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

Remove the seat (Sect. E 3, Removal of the seat).

Remove the tank covers (Sect. E 2, Removal of the fuel tank fairings).

Loosen screw (A) to remove hoses from cable grommet (B). Release tabs (C) from cover (D).

Remove the breather hose cover (E) (Sect. N 8, Removal of the generator cover).

Withdraw the breather hose (6) from the cover (E).

Withdraw the hose (6) upwards, leaving it attached to the tank breather and drain hose unions.

Working on the right-hand side of the motorcycle, disconnect the wiring connector (F) of the fuel level sensor from the main wiring harness, unscrew the screw (30) securing the side of the tank to the frame and recover the washer (31).

Remove the screw (13) and recover the washer (14).

Release the fuel hoses (18) and (19) from the clips (16).

Detach the lambda sensor cable (G) from tank flange cover.

Before removing the flange cover (20), make sure the tank (1) is empty and position a rag to collect any spilt fuel.

Raise the tank, remove the flange cover (20) by unscrewing the nuts (21) and disconnect the quick-release fittings (29) from the flange.

Removal of the fuel tank filler cap

To remove the fuel filler cap assembly from the fuel tank proceed as follows.

Remove the tank covers (Sect. E 2, Removal of the fuel tank fairings).

Open the filler cap.

Unscrew the outer screws (3) securing the ring nut to the filler cap recess.

Remove hoses (4) and (7) from the filler cap assembly (2).

Remove the filler cap assembly (2).

Refitting the filler cap

Position seal (32) in tank cap (2) as shown and reassemble following the removal procedure in the reverse sequence.

In particular, tighten the screws (3) to the specified torque (Sect. C 3, Frame torque settings).

Removal of the fuel tank flange

Unscrew the screws (28) and (22) securing the fuel tank flange (23).

Remove the flange (23) from the tank.

Recover the O-ring (24).

Using the appropriate commercial tool, undo the clips (26) next to the fuel filter (25).

Remove the old filter from the connecting hoses and fit a new filter.

Before reassembly, carefully remove any deposits or scale from all parts.

When installing the filter (25), position it so that the arrow on the external housing is pointing towards the flange.

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

Insert the flange (23) in its housing in the fuel tank.

Fit the four screws (28) and tighten them to the specified torque (Sect. C 3, Frame torque settings).

Start the two screws (22) in their thread, with the side where threadlocker has been applied facing the flange, and tighten them to the specified torque (Sect. C 3, Frame torque settings).

Refitting the fuel tank

If the fuel tank has been disassembled into its component parts, reposition all the parts as shown in the exploded view. In particular:

tighten the screws (10) and (17) to the specified torque (Sect. C 3, Frame torque settings).

Refit the tank by engaging pins (H) on mounting brackets (9) and (12) into their seats on the frame.

Smear the O-rings (L) installed on fuel hose couplings (29) with rubber lubricant.

While holding the tank in the raised position, connect the quick–release fittings (29) of the fuel outlet hose (18) and return hose (19) to the flange:

fit the fuel outlet hose (18), orienting it as shown in the figure, inserting the fitting (29) in its union in the flange (identified with the word “OUT”), until you feel a click;

fit the fuel return hose (19), orienting it as shown in the figure, inserting the fitting (29) in its union in the flange (identified with the word “IN”), until you feel a click.

Attach the fuel hoses (18) and (19) to the clips (16).

Refit the cover (20) and start the two nuts (21) onto the two screws (22) then tighten the nuts to the specified torque (Sect. C 3, Frame torque settings).

When installing cover (20), ensure hoses (18) and (19) and wiring (M) on flange stay inside the cover jut (N).

Connect the fuel sensor (F) to the main wiring harness.

Route the lambda sensor cable (G) in the relevant rear tab available on the tank flange cover.

With the fuel tank lowered, the fuel pump connector (O) should rest on the vertical cylinder head, as shown.

Secure the tank to the frame with the screw (30) and the washer (31).

Tighten the screw (30) to the specified torque (Sect. C 3, Frame torque settings).

Secure the tank to the subframe with the screw (13) and the washer (14).

Tighten the screw (14) to the specified tightening torque (Sect. C 3, Frame torque settings) while holding with a size 5 Allen wrench the threaded insert (H) located on the top of the tank.

The threaded insert (H) is not present in the USA version.

Locate the breather/drain hose (6) on the motorcycle and refit the cover (E) on breather hoses (Sect. N 8, Reassembly of the generator cover).

Lay hoses into retainers (C) of cover (D) and fasten retainers. Position the hoses into cable grommet (B) and tighten the screw (A) to the specified torque (Sect. C 3, Frame torque settings).

Refit the tank covers (Sect. E 2, Refitting the fuel tank fairings).

Refit the seat (Sect. E 3, Refitting the seat).

Positioning of the fuel tank breathe/drain hoses

Positions of the fuel hoses connecting the fuel tank to the throttle body