OK Ron,
I'll try to remember how Blacktopper and I did this. First unhook the ground from your battery.
Then you have to drain the tank by removing the gas cap, then put the hose into a four or five gallon container. Put some masking tape on the tank under the speedo housing. Look underneath the tank and undo the wire connection that powers the fuel pump. Look carefully and you'll see how it unclasps.
Then you have to remove the bolts holding the tank on the frame. Cant recall if I waited to disconnect the fuel pump because I wanted to use the pump to to drain the tank...cant recall how we did that.
The rear of the fuel tank elevates, and the front of the tank rises a little too (be careful not to hit the speedo housing). On my bike, we actually had to pry the rear of the tank to get it to move upward--I'm thinking a little warm soapy water might have helped--once I got it out and cleaned up it was no further issue. Be careful getting the tank off the bike, esp if you didn't remove the speedo housing. Basically the tank has to come up and rearwards. Don't lift the back too high, just enough to clear the 'saddle that it rests on. Basically , once you get the bolts removed from the frame, the tank is just sitting on the frame rail, with a plastic saddle keeping it in place.
I wound up with a bit of gas still wanting to make a mess, so I took the thing outside and dumped the cup or so of gas in gravel and rinsed the tank with water, and then and blew it out with compressed air.
Then put the tank upside down on a towel and removed the 8 or 10 allen screws holding in the fuel pump itself. Be careful getting it out, as the filter kind of snakes around in the tank. Take a picture of it so you'll have the correct orientation when reassembling--or check the image in post 9 above.
I strongly urge you to contact The guys at BDM 316-260-8039 and buy a rebuild kit--it is cheap insurance....
The rebuild kit is straight forward, and the components you have to replace are easy to do. There is a short hose (maybe 3/4" long) that is not visible on the schematic above. It goes from the pump body to the supply line for the FI system. There is a little retaining wire and a clamp band on the body of the pump. Pry open the clamp band on the pump body with a screwdriver, being careful to not misshape it because you'll use it again (I tightened it by gently using side cutters and then a pair of channel locks because I didn't have the correct pliers to reinstall that clamp--worked out fine, just don't be too heavy handed. Put the little 3/4' hose on the supply line first, then attach the pump body itself into the hose. While the fuel pump is out, you should find a bore camera or some similar device and have a look around the tank. Mine had a little separation of the liner at the neck only and the rest was good. But you can be sure with a little lighted camera.
Then I went to all the trouble of reassembling everything but I rigged it so I could put the pump in a jug of fuel to be sure it worked OK. This is when I found out what 60 psi means.....haha. Won't try that again. Just re-install the rebuilt fuel pump and be careful to observe the manual's instructions on Torque and torque sequence. Put the tank together and put on your seat to be sure the seat and tank meet correctly, then bolt down the tank and hook up the battery and add fuel and fire away.
If I have any other thoughts, I'll post them, or maybe Blacktopper will notice something I forgot. Just take your time and study the parts...I was nervous to rebuild the fuel pump, but overall it was not difficult with the good instructions and schematics in the manual.
I think Paul Knowles and Viking (Kim) know a lot about this too and probably have some good pointers. too.
