SuzukiSavage.com - Fuel Tank

giom-650 Ex Member	Fuel Tank 11/17/04 at 08:23:36 How do you remove the fuel tank? Do I have to disconnect the fuel line? Do you have any photos?
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Max_Morley

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Re: Fuel Tank
Reply #1 - 11/17/04 at 19:55:23

No photo's. there are 2 bolts that hold the seat to the frame, in the corners, 10mm hex, lift the seat back up and slide it rearward. Then undo the speedo cable from the transmission being careful not to loose the sealing washer and noting how it is routed. Remove both the fuel line and vaccum line from the fuel control valve (danced around that one for the censor), remove the 2 bolts at the back of the tank, noting the relationship of the washers, grommets, and spacers. If you do want to scratch the paint tape off the frame near the vavle as it will have to be forced by the LH frame rail. then twist the tank clockwise and firmly pull it up and back. It will slide off 2 more rubber grommets in the front but need to have the wire harness from the speedo disconnected before completely removing it. Some one to help is very useful at this point, espically if the tank has much fuel in it. The connector has a retaining clip that will have to be depressed to release it. Pull the tank straight up get the speedo cable clear of the engine and frame area. After a couple times it is easy.

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Max at Thumper Acres. '96 Savage bagger, '03 Savage w/Cozy sidecar for wifeni.

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giom-650 Ex Member	Re: Fuel Tank Reply #2 - 11/18/04 at 05:47:25 Thanks, I'm getting ready to install a dynojet upjet kit to go with the SuperTrapp I installed.
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Gitarzan Serious Thumper 2004 No Login Offline ! Posts: 827 Columbus, Oh, Earth, Solar Sys Gender:	Re: Fuel Tank Reply #3 - 11/18/04 at 21:05:59 Note: the above procedure works for most tanks. There is some variance in frame width apparently. Maybe year to year, maybe day to day. My tank can come off that way, with much effort, but will not go back on unless the petcaulk is removed. I've heard of other bikes that it will not come off that way at all.
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PerrydaSavage

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Re: Fuel Tank
Reply #4 - 11/19/04 at 00:58:52

My '03 Savage is one of those Bikes ... have tried and tried, but cannot anyhow, anyway get my tank off (or on) unless I first drain it and then remove the petcawk (have to spell it that way, or evil censor will convert to pet-thingy ... which sounds even more perverse! Wink

) altogether. Removing the gas tank (particularly in order to service the spark plug) is one of my major pet peeves with the LS650 ...

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Fuel Tank Reply #5 - 11/19/04 at 07:03:07 I'll admit, I do have to twist and wrestle mine to get it off and the petco.ck does scratch the frame (which I'm about to reprimer and put electrical tape over) but it does come off.
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giom-650 Ex Member	Re: Fuel Tank Reply #6 - 11/30/04 at 11:20:27 I have the 2002. I had to drain the tank and take off the fuel valve to get the tank off. I removed the carb and upjetted with a dynojet. Everything is straightforward except removing the carb screws. Be careful.
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Savage_Greg

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Re: Fuel Tank
Reply #7 - 12/04/04 at 13:11:45

There haven't been any changes to the Savage frame between years. You may think that it won't come off without removing the petc_ock, but it will. You have to push it to the left after you raise it a little. No need to drain or remove.

Oh yeah, it will scratch the tank because it is just difficult to gently slide the tank off the bushing mounts

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cphilip Ex Member	Re: Fuel Tank Reply #8 - 12/04/04 at 19:33:02 Its Petcock. (the filter will not let me say that!) So include "Pet" and "Male Rooster".
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fuel Tank Reply #9 - 12/05/04 at 06:17:33 cphilip wrote on 12/31/69 at 16:00:12: Its Petcock. (the filter will not let me say that!) So include "Pet" and "Male Rooster". Petrooster? (a rooster is male )
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Doug Keely Guest	Re: Fuel Tank Reply #10 - 12/07/04 at 18:16:28 Just finshed removing my tank on my 95 LS650. I had to pull it in the direction of the "fuel vavle" and toward the back of the bike. Also had to remove driver seat first. Don't know how similar your 03 is so this may not help. Actually, getting it back on was much harder. Later
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giom-650 Ex Member	Re: Fuel Tank Reply #11 - 12/08/04 at 05:40:57 It's much easier when you drain the tank and remove the petkock, 2 screws. Also, you can turn the tank upside down after removal for speedometer access.
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Smoknweelz

Ex Member

Re: Fuel Tank
Reply #12 - 04/15/05 at 18:52:29

Well, I suspected I had a Fouled Spark plug and the internet gods sent me to you guys....

I tried with a little help from my friend... and y'all's advice, and thanks to all the hints, removal was actually easier than I thought it'd be.
So to say thank you, Here are the Pics I took of the process...

First Remove the Seat and 2 rear screws that hold the tank down as described very well above,

Then disconnect the Tranny Cable...

http://predator.bikepics.com/pics/suzuki-savage-98-bikepics-332731.jpg (Bigger version)

Next Disconnect the Air and Fuel lines...

http://predator.bikepics.com/pics/suzuki-savage-98-bikepics-332733.jpg

Now Shimmy and Shake, Wiggle and Twist, it is best to have a buddy at this point to hold the bike from falling...

There are simply 2 rubber bumpers you need to slide it off of to get the tank to remove. Once it is in your hands, you will see the Speedo Wire you will need to disconnect. And Viola You've done it!

http://predator.bikepics.com/pics/suzuki-savage-98-bikepics-332734.jpg

To put it back on takes a few bad words, but keep in mind the idea is to get it back onto the rubber bumpers, at this point I held the bike still from the seat area, and my friend pulled the tank toward him in place. It slid right on when the alignment was just right. Good luck guys!

Oh and for the record, It Was just a fouled plug, Cleaned it and the Bike started right up!

Later,
Smokn~ 8)

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WD Serious Thumper 2005 No Login Offline Professional "scooter trash". Posts: 5207 Rosemark TN Gender:	Re: Fuel Tank Reply #13 - 04/15/05 at 19:22:40 Grease the front rubber bushings AND the on tank pockets. Use Crisco or such, regular old grease will eat the rubber. Takes all the fight out of the re-install. -WD Although you'll still end up cussing the designers when you squash your fingers under the rear of the tank. -WD
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thehoghunter Full Member 2004 No Login Offline Chop Suey Posts: 181 Tampa Gender:	Re: Fuel Tank Reply #14 - 04/15/05 at 20:08:59 And when you removed the 'tranny cable' (the speedometer cable) did you make sure you didn't lose the o-ring washer for it?
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