best way to get plug out of fuel tank?

[husafreak]

Dumb Q. I bought a fuel magnet for my 600N, but I convinced myself I was going to tear the tank apart trying to remove the stopper. Is there a trick to getting it out? On my Raptor it's easy but this sucker is tight. Thanks

[joco]

Ask ClayK... I spent the weekend with him doing this EXACT same thing.

[ClayK]

Ask ClayK... I spent the weekend with him doing this EXACT same thing.
This exact maintenance function is my least favorite aspect of my 600 (other than this one thing, I love my 600).

This isn't the only way, but this is how I did it. It was a royal pain, let me tell you.

Wiggle the plug out of the grommet. It's tough, but should come out. You can't get the clunk out with the grommet installed so you might as well pull the line off the plug and drop the clunk and line into the tank. Carefully pull the grommet out and then use a set of either curved or straight hemostats to pull the remaining portion of the clunk assembly out of the tank. Ok, now everything is out of the tank. Pull the stock clunk off the clunk line and replace with the ELD/Fuel Magnet/whatever. NOTE: I suggest cutting off a thin ring off the clunk line to wrap around itself to tighten the clunk line on the nipple of the ELD/Fuel Magnet/Whatever. Think of it as a collar. Ok, now thread that clunk line through the grommet. Partially install the plug into the grommet. When I say partially, I mean partially. Just a half of the circular edge should be in the grommet. The point is you can't get grommet and plug out at the same time. Once the plug is partially threaded, start putting in the grommet. It's a tight fit, but it can be done. Once the grommet is about to sink in, work that plug further in. If things aren't too slippery, you might be able to install the plug into the fully installed grommet. I wasn't this lucky however.

[rcmarty]

Try it backwards .... I know .. i thought the same thing at first.

Put the rubber part into the tank then put the center in it, with the large section on the outside of the tank you have a bit of something to hang onto.

Try it .. i did and i'm converted !

Martin :)

[jack726]

Darn near drove me crazy trying to get it. I then completely installed the plug into the grommet, applied a bit of oil and with a turning motion installed the whole thing in 10 seconds.

Jack

[WayneBrown]

I assemble it, and jam it all in too. Works better without the hassle.

[jgeorgic]

This exact maintenance function is my least favorite aspect of my 600 (other than this one thing, I love my 600).

This isn't the only way, but this is how I did it. It was a royal pain, let me tell you.

Wiggle the plug out of the grommet. It's tough, but should come out. You can't get the clunk out with the grommet installed so you might as well pull the line off the plug and drop the clunk and line into the tank. Carefully pull the grommet out and then use a set of either curved or straight hemostats to pull the remaining portion of the clunk assembly out of the tank. Ok, now everything is out of the tank. Pull the stock clunk off the clunk line and replace with the ELD/Fuel Magnet/whatever. NOTE: I suggest cutting off a thin ring off the clunk line to wrap around itself to tighten the clunk line on the nipple of the ELD/Fuel Magnet/Whatever. Think of it as a collar. Ok, now thread that clunk line through the grommet. Partially install the plug into the grommet. When I say partially, I mean partially. Just a half of the circular edge should be in the grommet. The point is you can't get grommet and plug out at the same time. Once the plug is partially threaded, start putting in the grommet. It's a tight fit, but it can be done. Once the grommet is about to sink in, work that plug further in. If things aren't too slippery, you might be able to install the plug into the fully installed grommet. I wasn't this lucky however.

I wanna see you do that after a few pops. Should be a snap :thumbup:

[erniefritz]

Wayne , i do it your way too. just assemble it, get it good and wet with fuel and put the whole thing in in one turning motion....

[ClayK]

I tried the whole assembly assembled turning thing. I couldn't get it into the tank hole, wouldn't squeeze in. Mine was oiled from fuel which seemed to be enough to push the grommet in by itself when I tried to squeeze the plug into the already assembled grommet. I've seen people do it the way Wayne mentioned, just didn't work that way for me.

[milesale]

Is there a trick to getting it out?

I just went through this when I got my fuel magnet. For me, the easiest way to get everything apart was to push the plug and grommet inside the tank together, then reach in with a pair of needle nose pliers and pull the grommet off the plug and out of the tank. Then everything else comes out pretty easily.

[WayneBrown]

got more practice last night with another new 600N, tried the other ways mentioned here, and successfully failed repeatedly. What works for me, still works for me. ;)
This was on a virgin assembly, no oil or fuel. Kept pushing the damn grommet thru the hole.
Finally assembled the whole deal and jammed it in, First try.
Of course I did squeeze the top of the tank and remove it from the frames, I couldn't get it in with tank in frame using any method. Must be a leverage thing.

[husafreak]

Thanks. I'm going out to the garage now, wish me luck!