How do you remove the fuel tank from a 1996 Suzuki Savage LS 650? I have the owner's manual and Clymer manualbut neither properly explains it.Does the fuel valve have to be removed?
There should be a bolt towards the bottom of the tank. You will have to remove Your seat to see it. Undo the bolt and slide it out. Shut off the (petcock) fuel valve first. You don't need to take off the fuel line. There should be 2 other hoses under it aswell. You may need to reconnect them if they come off.
I just did this on a 2008 S40, which is basically the identical bike. Remove the seat with one hex bolt in the rear and a 10mm bolt on each side. That exposes two more 10mm bolts and a hold-down on the rear of the tank. Remove those two bolts.
Now, disconnect the fuel line to the carb and a second breather line that attaches to the fuel selector switch. Draining the tank from the hose into a container by putting the fuel selector on "prime" makes life easier. Now, with the tank drained, pull the tank rearward and slightly to the rider's left side in a wiggling motion. The front of the tank has two receiver slots that wedge onto rubber donuts . Once the tank comes rearward a bit, you can pull up in a firm motion and the tank will come free. Finally, have a helper hold the tank sideways so you can reach up to unscrew the speedo cable and disconnect the gauge electrical connector.
hey john painter!!!!!! thank you for your advice on the receiver slots. it actually felt like the tank was fixed to the frame somewhere i couldn't see. i don't know why the clymer doesn't say this. i put a little more muscle into and rocked it from side to side and it viola! the tank was off. you may have very well saved me hours of futile work,
i am having a problem indentifying what all four leads out of the tank are on a 99, any ideas? and if some of them are missing would that cause excessive leaking?
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