How do you remove a virago xv535 fuel tank?

Answer 1

All XV535s have an under-seat tank. Where early models (filler under the seat) have a dummy cover in the conventional tank position, later models have an additional upper tank and filler cap. Read this through a couple of times and identify all the processes/parts before you start. Run the bike as low on fuel as possible. Remove the seat by removing the two 10 mm screws and lifting the seat up and back. Disconnect the battery. Remove the three screws holding the upper tank (later model only) one at the rear, one on either side toward the front. Lift the tank, disconnect the hoses and remove the tank to a safe place, paint costs! Remove the hoses from the top of the under-seat tank. [On early models remove the filler cap disconnect the overflow pipe from the rubber tank cover and remove it.] Remove the left hand side cover to expose the pump, filter and tank connectors. Label and disconnect all pipes and electrical connectors. Remove the three screws holding the left passenger peg bracket (two to the left and forward of the peg and one above) and remove the bracket and peg in one piece. You could take the pump off now if you wish although it is not necessary. Inboard of the seat rails remove the tank securing bolts and large rubber damper washers. After a final check to ensure all pipes and connectors are removed, slide out the tank (and pump if still fitted) through the left side of the frame. Remember: Tanks hold an explosive gas air mix and can easily ignite. Always work in a well ventilated area and avoid the use of exposed steel cap shoes, grinding and welding equipment and naked flames (like the pilot system on the gas central heating boiler in your garage) in the vicinity of open tanks.