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Changing spark plug on 2005 suzuki 650 s40

I cannot seem to get the gas tank moved backward so I can get to the spark plug. Any tips on this?

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  • Suzuki Master
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5/8 or 13/16 socket with hex hea for use with a wrench, not rachet. good luck

Posted on May 24, 2009

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Changing the spark plug is a real treat. First, buy a good Iradium plug, you will be thankful as they are far superior to stock ones. Second, remove the seat, Third, remove the gas tank, [fuel line also with the full turned off, then remove the speedometer cable at the top of the crankcase cover on the right side, tape off the end of the cable cause you don't want to loose the end of the cable, then while lifting the gas tank off unplug the wires underneath the tank]. Fourth, remove the top engine chrome cover on the left top of the engine, au-ha there it is - the spark plug.
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How to remove the gas tank to replace the spark plug. I have already removed the seat and couple of screws. I have lifted and pushed down the gas tank but could not pull enough to reach spark plug. Please...


This has been answered elsewhere, but I'll reiterate. There are two bolts holding down the rear of the tank. Remove them and, assuming you've already disconnected the fuel lines, pull backwards and upwards on the tank at the same time, with a slight bias to the left. There are two rubber donuts in the front which the tank is just wedged onto. When the tank comes free, you still need to disconnect the harness and the speedo cable underneath.

Apr 01, 2010 | 2005 Suzuki Boulevard S40

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I need to change the spark plug on my 1996 suzuki savage , I have removed the seat as well as the 2 bolts that hold the gas tank under that seat ,having trouble from there it won't lift off help please


I took mine off last night for the first time. Once you remove the 2 bolts at the back of the tank then you have to work it loose. generally pull up and back on the rear end of the tank, and then up and to the left as it starts to loosen. The reason you need to pull to the left is that the fuel selector valve will start to interfere with the throttle cable once the tank moves backward, and twisting the back of the tank towards the left will let the valve go around the cable. Take a look and you'll see what I mean. Took a while working it back and forth to get it off, but I finally did. Some people recommend you drain the tank and remove the fuel valve as an alternative but I didn't need to do that.

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How do I change spark plug of 2005 suzuki s40?


Remove the seat (three bolts). Drain and then remove the gas tank (two bolts in the front, pull backwards and to the left as you simultaneously pull up), and disconnect the gauge harness and speedo cable. Obviously you need to disconnect the fuel line from the tank too.

Now remove the left head cover and you'll have access to the plug.

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2 Answers

Bike wont start


I posted this for a similar problem, maybe it can help. Are you sure it's getting gas to the carbs? Some people don't realize the 99-02 SV650 has a vacuum-actuated fuel pump, and sometimes it can get stuck. Mine has had this problem, and it took me a while to determine it was the problem. I would guess it only happens after the bike has been sitting a while (ours unfortunately sat for a year or so without being run).

Best way to check it is to lift the tank (it's bolted to the frame on the right side of the engine just under the tank). Unplug the line toward the front of the motorcycle from the fuel pump, and connect some spare fuel hose to it running to a can next to the bike (don't want to get gas everywhere!). With everything else still connected, crank the bike for a short period to see if any fuel comes out (shouldn't take long). If not, then move backward and ensure fuel will flow from the vacuum-petcock when the bike is cranked. If that does work, your fuel pump needs some work. I was able to take mine apart and unstick it.

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