KTM 1290 Adventure - How to Remove the Fuel Tank

Removing the fuel tank on your KTM 1290 Adventure is a necessary task to do for deeper work on the bike, or for things that aren’t that deep, such as changing the air filter. Don’t get me started. It might seem intimidating on the surface, but it’s really not that bad and requires no special tools or skills.

One suggestion before doing this job. The less fuel in the tank the easier it is to lift off and move around. I would highly recommend having a 1/4 tank of fuel or less when doing this task.

Prep Work

There are a few steps that need to be completed prior to removing the fuel tank. Click on the articles below for detailed instructions.

1. Remove the Seat
2. Remove the Side Panels
3. Remove the Fuel Tank Cover
4. Remove the Mask Spoiler

Tools Needed

• T40 Torx
• 6mm Hex Socket
• 3” Extension
• Ratchet
• Needle Nose Pliers
• Small Flat Head Screwdriver
• T30 Torx or 8mm Wrench (optional)

Steps for Bottom Side of Fuel Tank

1. Close both of the fuel shut off valves. There are two of them located on the right and left side of the bottom of the fuel tank. Turn them clockwise to close.

2. Remove both of the rubber cable ties holding the fuel line and the electrical cable together.

3. Remove the metal clips securing the fuel hoses to the shut off valves. Use a needle nose pliers to compress the clip and slide them completely off the shut off valves. Once the clips are off, pull the fuel hoses off of the shut off valves. There will be a small amount of fuel that will run out of the hoses, so have a shop towel ready to absorb the fuel.

4. Clean the area around the main fuel line. You do not want to get any dirt or debris in the fuel line. The main fuel line has a quick disconnect. Press down on the metal clip in the center and separate the top and bottom pieces. There will also be a little fuel in these lines, so have a shop towel ready to absorb the fuel.

5. Disconnect the electrical connection for the fuel pump. Use a small flat head screwdriver to press down on the tab on the electrical connection and separate the electrical connection.

Steps for Top Side of Fuel Tank

1. On the right side, cut and remove the cable tie holding the vent line and electrical wire together. Use a needle nose pliers to compress the clip on the vent line and slide back. With the clip back pull off the vent line. On the left side pull off the other vent line.

2. Disconnect the electrical connections on the top right of the tank. For the small, white connection use a small flat head screwdriver to press down on the release and separate the connection. For the larger, black connection pull up on the release tab and slide the connection off to the left.

3. With a 6mm hex socket, remove the bolt and rubber bumper at the top center of the fuel tank.

4. With a T40 Torx, remove the bolts and bushings on the rear, sides of the fuel tank. There is one on both the left and right side of the fuel tank.

5. Optional Step: KTM recommends removing the rubber bumpers on each side of the fuel tank. I personally leave them on and have no issues, but I will leave that decision up to you. If you would like to remove them, use a T30 Torx or an 8mm wrench to remove the bolts on each bumper. There is one on both the left and right side.

Remove the Fuel Tank

Slide the tank around a little bit, so that you can get your hands underneath the front center and the rear center of the fuel tank. Lift the fuel tank up and slightly back to remove the tank from the bike.

Caution Spot: When lifting the fuel tank up and off the bike, be careful with the ends of the front fairing that stick out over the tank. It is easy to pull the tank up into one of those and break the end off when removing.

That’s it. That is all there is to it. Now you can actually change your air filter.