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VMAX ab Baujahr 2009 - RP21

Tank 21,5 and 24,5 litres
Parts list:
1st tank
2. fuel pump extension
3. cable pull
4. brake container bracket - hose with extension
5. mounting parts

Installation instructions with sufficient picture material

Set up the motorcycle safely so that it cannot fall over!

Mountingtime 6-8 hours.

Disassemble the series tank in the order listed:
- Seat
- pillion
- Left side cover
- Right side cover
- Tank ventilation incl. activated carbon filter
- Left luggage compartment plastic, to be modified later, pictures 31-34
- Electric carrier plate right (only release)
- Remove wheel arch plastic rivets
- Wheel arch plastic 1
- Wheel arch plastic 2
- license plate holder
- Rear fender complete
- Connection cable rear light and indicator
- rear light
- Alternator regulator plug
- Fuel pump connector plug
- fuel line
- Disconnect Exup motor
- Bowden cable for tank opening
- mufflers
- pillion ratchet carrier
- Remove the 4 main fixing screws from the rear of the frame.
- of the complete frame rear incl. tank
- Wheel arch plastic 3 has to be modified later, pictures 1-4
- Remove the tank from the rear of the frame.
- Remove the tank retaining rubbers from the rear frame.
- the fuel pump
- of the fuel pump unit Assembly of the pump intake extension Figs. 17-23
- of the fuel filler neck

Assembly of the new tank:
- Modification of the wheel arch plastic, pictures 1-4
- Stick damping tape or modified original rubber onto the rear frame struts
- Pre-assembly of the modified wheel arch plastic
- Assembly of the modified fuel pump using the standard components incl. gasket
- Assembly of the fuel filler neck using the standard components incl. gasket
- Position the seat bowden cable at the rear of the frame:
- The cable pull must be laid between the tank and the frame before the tank is mounted in the frame.

Installing the new tank in the rear frame
Frame rear on main frame Mounting
(for the time being only with the upper two fixing screws)

To install the tank in the frame is better to do with 2 people.

- Raising the rear of the frame and mounting the wheel arch plastic 2
- Lower the rear of the frame and fix it by screwing in the lower
both fixing screws
- Laying the alternator regulator cables,
- Rear light and turn signal connection cable in standard position.

- Assembly of the wheel arch plastic in connection with the license plate holder.
- Mounting of the modified seat linkage Bowden cable
- Connecting the seat Bowden cable
- Mounting the rear light and connecting the connecting cables
- Repositioning and assembly of the brake fluid compensation reservoir

Mounting the passenger footrest carrier,
Exhaust pots,
Exupmotor if available
Electric carrier plate right,
Left luggage compartment plastic,
Seat and pillion seat,
side cover

Attention!
Only start the engine after first filling the new tank, so that the fuel pump does not run "dry".

Translated with www.DeepL.com/Translator

Fig. 1 -4 Cut out underbody, e.g. with a Dremel or similar tool

Plastik Vorn/ Plastic front

Fig. 5 -8 Cut out the underbody using the suspension strut.
Remove all rubber distances.

Picture 9-13
Enlarge the existing bore so that the supplied rubber nut fits suckingly.

Picture 14 - 15 -16
Cut the heat protection open and remove the clamp.

Fuel Pump/Petrol Pump
Fuel pump extension, fuel pump below loosen and remove the white plastic clip
Use a small screwdriver to lift out the circlip.
Put on the extension and tap it carefully with a plastic or rubber hammer.
Mount the screw with both lock nuts, please tighten it only so that it sits backlash-free !
Figure 17-21

Float Stand
The float stand can, but does not have to, carefully bend the boom by hand.
until the specified dimension is reached.
If the float is left in series condition, the reserve indication is very inaccurate !
Fig. 22-23

Seat lock cable.
The serial cable can be used,
if the thick sheathing is cut open lengthwise with a cutting knife and removed.
Install the cable supplied as an alternative to the standard one.
Picture 24-30

Bend the holder rope pull outwards.

Left side cut out plastic fairing to fit Picture 31-34

Mounting overflow - Fig. 25

Use of the original rubber distances.
These must be cut to fit.
Alternatively, a rubber band 2-4 mm thick with double adhesive tape can also be attached.
Picture 36 - 45