DIY: Install a Motorcycle Gas Tank on the 2008 Ninja 250
- 1). Remove both frame covers, located under the rider's seat and fuel tank, from the motorcycle. Unscrew the bolt from the bottom of the cover, using a 5 mm Allen wrench. Pull the tabs under front of the frame cover, near the fuel tank, away from the motorcycle's frame. Slide the cover towards the front of the motorcycle to free its tabs from the tail fairing. Remove the remaining frame cover, using this method.
- 2). Unscrew the mounting bolts from both sides of the rider's seat, using a 5 mm Allen wrench. Pull the seat forward to free it from the mounting bracket attached to the frame.
- 3). Remove the plastic rivet clips from the bottom of the lower side fairing panels. Press the center pin down and into the clip body, using a punch or the tip of a Phillips screwdriver. Grasp the clip body with your fingers, then pull the entire rivet clip out of the lower fairing. Push the center pin up until it protrudes from the top of the clip body for later reinstallation.
- 4). Unscrew the mounting bolts from both lower fairing panels, using a 5 mm Allen wrench. Pull the panels away from the motorcycle's frame.
- 5). Unscrew the fuel tank mounting bolts, located near the rider's seat mounting point, using a 10 mm socket and a socket wrench. Lift the rear of the fuel tank up slightly and unplug the fuel lines from the fuel valve under the left side of the tank. Pull the vacuum hose off the rear of the fuel valve.
- 6). Connect a 3-foot-long piece of 3/8-inch plastic tubing to the fuel valve's center outlet. Place the opposite end of the tubing into a 5-gallon gas can. Turn the fuel valve tap to the prime position, shown as "PRI," using a flat-head screwdriver. This will allow the tank's store of gasoline to drain freely through the valve and into your gas can. Allow the tank to drain for at least 10 minutes. Shake the tank periodically to ensure that it drains completely. Turn the valve tap to the "On" position once the tank has drained. Pull the tubing off the valve outlet.
- 7). Lift the tank slightly, then pull it toward the rear of the motorcycle to free it from the forward mounting dampers. Unplug the fuel gauge sender connector from the bottom of the tank.
- 8). Remove the fuel valve for installation on the new fuel tank, if the new tank is not already equipped with one. Unscrew the fuel valve mounting bolts, using a 10 mm socket and a socket wrench. Pull the fuel valve out of the bottom of the fuel tank. Slide the valve into the bottom of the new tank. Screw the valve mounting bolts into place, then tighten the bolts to 22 inch-pounds with a torque wrench.
- 9). Slide the catches at the front of the fuel tank over the frame's mounting dampers, located along the motorcycle's frame near the handlebars. Plug the fuel gauge sender connector into the bottom of the fuel tank. Reconnect the fuel lines and vacuum hose to the fuel valve. Lower the fuel tank onto the frame, then screw the fuel tank bolts into place with a 10 mm socket and a socket wrench.
- 10
Mount the lower fairing panels onto the motorcycle, using a 5 mm Allen wrench. Join the bottoms of both panels, using the plastic rivet clips you removed earlier. Push the clip into the fairings, then press the clip's center pin down until it is flush with the clip body. - 11
Slide the rear of the rider's seat into its mounting bracket, then lower the seat into place. Screw the seat mounting bolts into both sides of the frame, using a 5 mm Allen wrench. - 12
Reinstall the frame covers. Slide the tabs at the rear of the cover into the slots cut into the tail fairing. Push the tabs at the front of the cover into the motorcycle's frame. Screw the cover mounting bolt into place, using a 5 mm Allen wrench. - 13
Open the fuel tank filler cap. Fill the fuel tank with fresh gasoline, or reuse the gasoline drained from the original fuel tank. Lock the filler cap into place.
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