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Old 12-13-2009, 03:33 PM
yz400ex yz400ex is offline
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Default fuel tank recall?? How to remove fuel tank?

I am wanting to know a little more about the fuel tank recall.. I noticed today that mine is cracked around the cap area so its leaking a little.. What was the recall for? How do I know if it has or hasnt already been repaired with the replacement tank? If this repair isnt covered and I have to replace the tank myself, How hard is it to remove and what if any special tools do I need?
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Old 12-13-2009, 03:40 PM
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I don't know what the recal was for as it was already done when I got mine. I would check with a good dealer nearby and ask them if they will cover it under warranty. (good luck)
It is pretty simple to remove. You will need a fuel line disconnect tool set which you can pick up from Napa or the like for under 15$ Remove the console, remove the rear compartment and unbolt the tank, use the disconnect tools to pop the lines apart and disconnect the wiring connector and it will slide out.

On the way home

Last edited by ghostwhite; 12-13-2009 at 04:06 PM.
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Old 12-13-2009, 04:04 PM
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The update was a glue in insert into the neck
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Old 12-13-2009, 04:07 PM
ghostwhite ghostwhite is offline
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Heres the Tool

On the way home
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Old 12-13-2009, 04:36 PM
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Quote:
Originally Posted by jtpolaris View Post
The update was a glue in insert into the neck
That was the first recall. Then Polaris recalled the entire tank. The tanks filler necks were cracking and would let dangerous fumes and gas out.

Here's a link about the recall.
http://www.snowmobile.com/news/polar...azard-533.html
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Last edited by 94fordguy; 12-14-2009 at 03:58 PM. Reason: Fixed quote coding
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Old 12-13-2009, 05:21 PM
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so mine is cracked around this filler neck.. Is there anyway I can tell if this was a replacement tank or if it is still covered under the recall warranty?
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Old 12-13-2009, 05:23 PM
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Quote:
Originally Posted by ghostwhite View Post
Heres the Tool
How is this tool even used?? Will I need to relieve the pressure in the line prior to disconnecting the lines?

Does anyone know where I can find a diagram of the fuel lines being disconnected and the process for doing so?
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Old 12-13-2009, 06:30 PM
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There's 2 lines that need to be disconnected. The one with the fuel filter attatched right behind the secondary clutch towards the engine and the second is the supply line coming out of the tank. The tool pushes down some tabs that connect the metal fuel lines and you just pull them apart. A little bit of pressure will relieve when you disconnect the lines, most of the pressure is in the fuel rail. You may have to prime the pump to get to pressurize the lines when done.
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Old 12-13-2009, 06:32 PM
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take thew vin # to a dealer and they can tell if it was ever done,and it should be still covered as my dealer just did one for us.
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Old 12-13-2009, 06:40 PM
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Old 12-13-2009, 06:58 PM
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Old 12-13-2009, 09:29 PM
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Old 12-13-2009, 10:05 PM
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Old 12-14-2009, 04:18 PM
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Old 12-14-2009, 06:46 PM
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