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.
- Rear stand (recommended)
- Phillips screwdrivers
- Hex wrenches
- Long-nose pliers
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 could spill a small amount of gas from in 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 four hex bolts, two at the front and two at the rear. It is also connected to the bike by the gas line and by an electrical pickup.
First, you must remove both seats. Then: