Honda CR80R Fuel Tank Removal Guide

Getting Started with Your Honda CR80R Fuel Tank Removal

The Honda CR80R is a legendary motocross bike, and like any machine that sees regular use, it will eventually require maintenance or repairs. One of the most common tasks that might necessitate removing the fuel tank is accessing the carburettor for cleaning or jetting, or perhaps replacing a faulty fuel petcock. While it might seem a daunting task for the uninitiated, with the right guidance and a methodical approach, removing the fuel tank from your Honda CR80R is a perfectly manageable DIY job. This guide will walk you through the process step-by-step, ensuring you can safely and efficiently get the tank off your bike.

Before you begin, it's crucial to gather the necessary tools and prepare your workspace. Ensure you have a clean, well-lit area to work in, free from distractions. Safety is paramount when dealing with fuel, so make sure there are no open flames or sparks nearby. Having a fire extinguisher readily accessible is also a wise precaution.

Essential Tools and Preparations

To successfully remove the fuel tank from your Honda CR80R, you'll need a few basic tools. Having these ready will make the process smoother and prevent unnecessary delays:

• Screwdriver Set: You'll likely need both Phillips head and flathead screwdrivers, in various sizes, to tackle different fasteners.
• Wrench Set: Metric wrenches, particularly in the 8mm, 10mm, and 12mm range, are commonly used on Japanese motorcycles.
• Pliers: A good pair of pliers, especially needle-nose pliers, can be useful for manipulating hoses and clamps.
• Fuel Container: A clean, approved fuel container is essential for safely storing the fuel you'll be draining.
• Rags and Paper Towels: For wiping up any spilled fuel and keeping your hands clean.
• Gloves: Nitrile or fuel-resistant gloves are highly recommended to protect your hands from fuel and grime.
• Optional: A small length of clear tubing can be helpful for siphoning fuel if your petcock isn't easily accessible for draining.

Preparation is key. Ensure the engine is cool before you start. Attempting to remove the tank on a hot engine can be dangerous and may damage components. It's also a good idea to have a stand to support the motorcycle securely, ensuring it won't tip over during the process.

Step-by-Step Fuel Tank Removal

1. Drain the Fuel Tank

This is arguably the most important step for safety. You cannot remove a fuel tank filled with petrol. There are two primary methods for draining the fuel:

• Using the Fuel Petcock: Locate the fuel petcock, usually found on the lower side of the fuel tank. Place your clean fuel container beneath the petcock. Turn the petcock to the 'ON' or 'PRI' (Prime) position. If the petcock is functioning correctly, fuel will begin to flow into the container. Once the majority of the fuel has drained, you can turn the petcock back to the 'OFF' position.
• Siphoning: If the petcock is difficult to access or you want to ensure all fuel is removed, you can siphon it. Insert one end of a clear tube into the fuel tank, ensuring it reaches near the bottom. Place the other end of the tube into your fuel container, which should be positioned lower than the fuel tank. You can start the siphoning process by mouth (be careful not to ingest fuel!) or by using a dedicated fuel siphon pump. Continue until the tank is empty.

Important Note: Dispose of drained fuel responsibly. Never pour it down drains or onto the ground. Take it to a designated hazardous waste disposal facility.

2. Disconnect the Fuel Line

With the tank drained, the next step is to disconnect the fuel line from the carburettor or the fuel filter (if fitted). The fuel line is typically a rubber hose connected to a nipple. You might find a small hose clamp securing it. Use your pliers or a screwdriver to loosen or remove the clamp, and then carefully twist and pull the fuel line off the nipple. Be prepared for a small amount of residual fuel to drip out, so have a rag ready.

3. Disconnect the Fuel Petcock (if applicable)

On some CR80R models, the fuel petcock might be a separate unit that screws into the tank, or it might be integrated. If it's a separate unit, you'll need to unscrew it from the tank. You might need a wrench for this. Be aware that there might be a gasket or O-ring involved, so keep an eye on these parts.

4. Remove Seat and Side Panels

Access to the fuel tank is usually gained by removing the seat and side panels. The seat is typically held in place by a bolt or two, often located at the rear of the seat. Once the seat is removed, you'll likely have better access to the fasteners holding the side panels. Remove any bolts or clips securing the side panels. On a CR80R, the side panels are usually quite simple to remove, often just a few bolts.

5. Locate and Remove Tank Mounting Bolts/Nuts

The fuel tank is secured to the frame by several mounting points. These are typically bolts or nuts. Common locations include:

• Front Mount: Often a bolt or a nut and bolt combination securing the front of the tank to the frame's headstock area.
• Rear Mounts: The rear of the tank is usually secured by two bolts or nuts that pass through rubber grommets or bushings to absorb vibration.

Carefully identify all these mounting points. Use the appropriate wrenches to loosen and remove the bolts or nuts. It's a good idea to keep these fasteners organised, perhaps in a small container, to avoid losing them. Note that some mounting bolts might have washers or specific orientations.

6. Disconnect Any Additional Lines or Wires

Depending on the specific year and model of your Honda CR80R, there might be other connections to the fuel tank besides the fuel line. These could include:

• Vent Hoses: Many fuel tanks have vent hoses that allow air to enter as fuel is consumed, preventing a vacuum. These are typically small rubber hoses. Carefully disconnect them.
• Electrical Connections: Some models might have a fuel level sensor or a warning light, which would involve electrical connectors. If you see any wires attached to the tank, carefully disconnect them by pressing the release tab on the connector.

Take your time and inspect the tank thoroughly for any other hoses or wires that might be attached before attempting to lift it.

7. Carefully Lift the Fuel Tank Off

Once all fuel lines, wires, and mounting hardware have been removed, the fuel tank should be free. Gently lift the tank upwards and away from the motorcycle frame. You may need to wiggle it slightly to disengage it from any rubber mounting grommets. Be careful not to scratch the frame or the tank during this process. It's often helpful to have a second person to assist with lifting, especially if the tank is heavy or awkward to manoeuvre.

Post-Removal Considerations and Tips

Handling the Removed Tank

Once the tank is off, place it on a stable surface, preferably on a piece of cardboard or a soft cloth to prevent scratches. If you plan to store it for a while, it's advisable to ensure it's completely empty and dry to prevent rust, especially if it's a metal tank. For longer-term storage, consider adding a fuel stabiliser to any residual fuel or even filling it partially with a fogging oil to protect the inside from corrosion.

Reinstallation is the Reverse

When it comes time to reinstall the fuel tank, simply reverse the steps you took for removal. Ensure all mounting bolts are tightened correctly but not overtightened, as this can damage the tank or the frame. Reconnect all fuel lines, vent hoses, and electrical connectors securely. Double-check that the fuel line is not kinked and that the petcock operates smoothly.

After reinstallation, turn the fuel on and carefully inspect for any leaks around the petcock and fuel line connections. Start the engine and let it idle for a few minutes, continuing to monitor for any signs of leakage. The first ride after reinstallation is also a good time to listen for any unusual noises and to ensure the fuel delivery is consistent.

Troubleshooting Common Issues

While the process is generally straightforward, you might encounter a few issues:

• Stuck Fuel Line: If the fuel line is stuck, try gently twisting it while pulling. A small amount of penetrating oil (applied carefully, away from open flames) around the nipple might help, but be cautious not to get it into the fuel line itself if possible.
• Stripped Bolt Head: If a mounting bolt head is stripped, you may need to use a bolt extractor tool or carefully cut a new slot for a flathead screwdriver.
• Leaking Petcock During Draining: If the petcock is leaking excessively when you try to drain, you might need to replace the petcock seal or the entire petcock unit.

Frequently Asked Questions (FAQs)

Q1: How much fuel should I leave in the tank before removal?
It is best to drain the tank as completely as possible to minimise the risk of spills and to make the tank lighter and easier to handle.

Q2: Can I remove the fuel tank without draining it?
No, this is highly dangerous and strongly discouraged. Always drain the fuel tank before attempting removal.

Q3: Do I need to disconnect the battery?
While not strictly necessary for fuel tank removal itself, it's good practice to disconnect the negative terminal of the battery when working on any electrical components or fuel systems to prevent accidental shorts.

Q4: What if my CR80R has a reserve fuel line?
If your model has a reserve, ensure you switch the petcock to the reserve position to drain as much fuel as possible. You'll still need to disconnect the main fuel line.

Q5: How do I know if I've reconnected everything correctly?
After reinstallation, carefully check all connections. Start the engine and listen for smooth running, and visually inspect for any fuel leaks. A test ride will confirm proper fuel delivery.

Removing the fuel tank on your Honda CR80R is a task that requires patience and attention to detail. By following these steps and taking the necessary safety precautions, you can confidently undertake this job yourself, ensuring your beloved motocross machine remains in top condition.

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