Honda rebel 250 - gas tank removal

BigJ · Aug 7, 2008

You will need to follow the steps in the link below to remove the seats before removing the tank.

http://www.hondarebelforum.com/showthread.php?p=7535#post7535

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Once you have the seats removed

First turn the gas to the OFF position on the petcock. See below.

Next slide the retaining clip on the fuel line away from the petcock. See below.

Next slide the fuel line off the outlet. be aware thet some gas will drain from the hose. See below.

Next remove the 12mm bolt holding the rear of the tank in place. See below.

Next remove the 10mm bolts on either side of the tank in front. See below.

Now you can remove the tank from the bike.

To remount the tank, reverse the process.

neatpleats · Apr 16, 2010

Thank you. That was easy. Now the fire department will stop complaining that I have a motorcycle in my store.

clareamalia · Nov 13, 2010

is it easier to drain the tank once it is off the bike?

Guba · Nov 13, 2010

It's best to drain the tank while it's on. But opinions may vary. Use a pair of pliers to squeeze the hose clamp open at the carb and pull the hose off. Then you can open the petcock (I assumed it was closed to begin with) and drain the fuel into an appropriate container.

clareamalia · Nov 13, 2010

sounds good-thanks

galvatron · Jun 26, 2011

Wow, it's that easy? this forum rocks, learning a ton. I might have my rebel custom painted

derpoodle · Aug 3, 2011

That is easy, I don't know why I was so intimidated... Now is there one more step for California bikes with a vent thingy?

ffces153 · Mar 5, 2012

Yes, lift the tank slightly remove/slide the hose clamp from the hose and remove the hose.

danloc78 · Nov 7, 2011

Does all the fuel need to be drained from the tank prior to removal?

irvintat · Nov 7, 2011

Not if you are going to put it right back on. Just make sure the petcock is off

Catzby17 · Mar 4, 2012

Thanks for the instructions, I easily removed the gas tank.
However when I went to paint it, i was cleaning it on its side, and some fuel began to leak from the cap. The petcock is off, no problems there and the cap is locked but it still leaks. Should there be some sort of seal that is missing?

Buickguy · Mar 4, 2012

No, your '85 vents through the cap.

If you wish to paint, you need to drain the tank of fuel first.
Just hook up a line, turn it to reserve and let it drain in to a gas can.

mojorisn · Mar 4, 2012

The classic Rebel have vented gas caps so if turned on it's side or upside down they will probably leak.

Catzby17 · Mar 4, 2012

Damn. Okay, thanks guys!

flitecontrol · Mar 5, 2012

It's hard to get all the gas out through the petcock. If you aren't going to remove it to paint the tank, use an old rag on a string to remove all the gas. Use a long screwdriver or ruler to get it where the gas is. The string will keep it from getting away from you.

Texas Reb · Mar 5, 2012

quick question. If you were draining to paint, would you need to coat the inside with something to keep rust at bay?

Catzby17 · Mar 5, 2012

I'm assuming that I can I paint the gas tank with gas inside of it?

mojorisn · Mar 5, 2012

You can, just be careful to not tip the tank over and run gas over your new paint.

Al Rebel · Mar 5, 2012

Say' sorry to steal this thread but just please one question,,

Does the 2005 have a vented cap ??

mojorisn · Mar 5, 2012

No only the classics have a vented cap.

BRFamous · Apr 19, 2012

Wow...... This looks so simple.. For some reason in my mind I assumed it would be harder therefore I have not attempted it yet...............

Running to the store tonight for paint!!! Gonna rattle can her for the time being and make sure the color scheme is what I want!!! (on my way to drain her right now!!)

MommaDukesLisa · Jul 28, 2012

Thank u, Thank u, this is awesome & so simple

Thank u so much for showing this step by step, very helpful

stick369 · Aug 27, 2012

New to the forum- I just got a '06, 250 with 1026mi, and I swapped the tank for a bigger 3.6gal. Took it for a test ride and there is a god awful racket at high RMP's. Figured it was some sort of vibration, and I was right, the new tank is hitting the frame. So I took a piece of rubber and put it between the tank and frame for a temp fix, need to ride to work tomorrow. Anyone else's tank touch the frame and what did you do to fix it?

mojorisn · Aug 27, 2012

Welcome to the forum. I have heard of that problem before. I think it's just a byproduct of some of the larger Chinese tanks. I'm not sure the best way to fix it but either leave it how you fixed it or use a spacer on the back mounting bolt to raise the tank in the back a little.

wjmrty · Aug 27, 2012

Welcome to forum .Yes had same problem on my rebel after my resto. fixed it by fitting a 3/8 in thick strip of reinforced rubber [car exhaust hanger strap] 4" long x 2" wide between tank n frame with bolt through centre ,stoped all vibrations in tank

fubar05 · Aug 27, 2012

how many miles till fill up now as opposed to b4?

stick369 · Aug 27, 2012

correction on last post, it's a 3.4 tank not 3.6, every drop matters. I got 122.5 on the last tank with about a half a gallon left to burn. I filled up last night, so this is the first full tank. I'm hoping for 200 per tank, if not more.

adoherty · Sep 11, 2021

I’m new to the forum and have to remove my tank to troubleshoot why my bike won’t start. When I follow the instructions above, I get to lifting the tank but there’s another hose that seems to be attached to something I can’t see or feel. Is that some kind of vent? How do I pull the tank with that hose too?

SoakedKarma · Sep 11, 2021

hose should slip off metal tube.. yes it is the vent hose

Honda rebel 250 - gas tank removal

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