VFR Discussion Group -> Replacing gas tank on Vtec

I'm getting ready to swap out the gas tank on my 03 Vtec. The tank has some dents in it from a previous owner and I've had a newer one sitting in my basement since the fall waiting to be installed. Just wondering is anyone has any experience with this or tips to make my life easier. I have the shop manual and it doesn't seem too difficult.
One question though. Can I remove the entire fuel pump assembly without bleeding any of the lines or will built up pressure be an issue? Also can this be done with gas still in the tank if it is turned upside down? If not any tips on draining the fuel? Thanks from the novice mechanic. :salesman:

I would drain the tank, I used a universal electric fuel pump from a car, you could just dunhook it and take it off and drain it but its alittle messy. If you turn the tank upside down it will leak.
When I took off my tank there was no pressure in the fuel line that I could see, I just removed it slowly, then unhooked the return line.
The hardest part was removing the fuel pump, you have to wiggle it around and force the steel mesh filter out. Be sure to buy a new rubber gasket for the pump, $6.95 from Honda.
The sending unit for the fuel gauge is pretty simple, just dont bend the lever while removing.

whylee, Apr 5 2005, 06:42 PMI would drain the tank, I used a universal electric fuel pump from a car, you could just dunhook it and take it off and drain it but its alittle messy. If you turn the tank upside down it will leak.
When I took off my tank there was no pressure in the fuel line that I could see, I just removed it slowly, then unhooked the return line.
The hardest part was removing the fuel pump, you have to wiggle it around and force the steel mesh filter out. Be sure to buy a new rubber gasket for the pump, $6.95 from Honda.
The sending unit for the fuel gauge is pretty simple, just dont bend the lever while removing.

What he said ! The pump is the hardest part, seems like it won't come out the hole, but it will !

I did mine on my '02 about a year and half ago. Same issues - a few dings. Third day I had the brand new bike - a dolt backed into the bike and tipped it over. :( OK - I won't go there. Back to your questions...

Its not too difficult. I think the primary pain in the arse for me was getting the remaining gas out of the tank so I could swap it out. I used a home made siphon and left a few ounces in the bottom. Removing the fuel pump assembly was tight and required a fair bit of trial and error. There is a mesh screen that, if I can remember this properly, surrounds the pump assembly and this makes it hard to extricate the pump from the tank. The float assembly also looks rather delicate - so I'd be easy on the pump when you remove it. I did not have to drain any lines or pressure. Looking at the other posts - seems they said the same stuff.

Good luck!

;)

I appreciate the replies. How critical is the gasket replacement. My son (first one) was just born on the 25th and I was hoping to get this done while I'm off taking care of him. Getting out of the house to a dealer might be a problem. I don't want to take any chances with fuel leaks so if dissembly damages it I guess I'll hold off till I get one. Also are the banjo bolt crush washers the same size as the ones for the brake system I have some extras laying around that I could use if they are. Thanks

We must have been typing at the same time Zenwhipper. Did you disconnect the fuel lines from the pump when you removed it or did you just leave it attached. I was hoping to just remove it from the old tank and screw it right back into the new one without messing with the connections.

Unhook all lines, it's not a problem unless you don't have a large allen wrench for the main fuel line. No way I would attempt it on the bike. Pull the lines, unplug the sensor and pump and set it down upside down on something soft so you can remove the pump and gauge sensor.

The only issue that I had was the lip of the fuel pump mount was bent to it leaked - A LOT. I took a hammer handle and reshaped the lip and the gasket seals it fine, now. I wouldn't have noticed the ripple in the lip had it not leaked - be very careful when putting the pump in that you don't tweak that orifice.

I didn't tear either gasket... I think I still have 'em in the garage (both pump and sender). If you can wait for USPS, I'll send them to you for gratis.