I am not a mechanic or a representative of Kawasaki or anything else official. This page is only my notes on doing this procedure myself. Although I believe what I have documented here is correct, I make no promises and you do this at your own risk.
Removing the gas tank on your bike allows access to the engine compartment, and is the first step in servicing the spark plug, cooling system, or the engine itself (e.g. valves).
- Rear stand (recommended)
- Phillips screwdrivers
- Hex wrenches
- Long-nose pliers
- Small container to catch the dribble of gas that comes out of the fuel line
Difficulties & Warnings
Warning: You’re handling a tank filled with gas (hence the name “gas tank”). Work in a well-ventilated area with no flames or sparks and don’t smoke or allow your visitors to smoke.
Some difficulties could be:
- You will spill a small amount of gas (a few ml) from the gas lines.
- You could spill a lot of gas if you forget to turn the petcock off.
- A full gas tank is pretty heavy, and can be hard on your fingers while lifting it out or setting it down.
- Apparently California-model bikes have additional hose connections because of their emissions regulations, so these instructions won’t be complete for those bikes.
The tank is held in place with two hex bolts at the rear and two plastic plugs in rubber grommets at the front. It is also connected to the bike by the gas line, a vacuum line, and an overflow drain hose.
First, you must remove the seat. Then:
Turn off the fuel petcock.
Next, double-check that the fuel petcock is in the off position.
Now, locate the short fuel hose connected to the petcock. Using long-nosed pliers to move the spring clip, remove the hose where it connects to the petcock.
A few ml of gas will spill out of the hose. Then leave the hose dangling in the bike.
Next we must remove the fastenings that hold the front of the tank. They are a small screw in the front fairing (circled at top here) and a snap plug behind the lower part of the front fairing (in the area circled at the bottom here).
These fastenings are on both sides of the bike.
Tug the lower rear corner of the front fairing away from the bike, releasing the plastic plug that is pressed into a rubber grommet on the tank (circled in green here — click to enlarge).
Repeat this with the screw and snap plug on the other side of the bike.