Kenny G wrote on 01/16/15 at 07:59:34:


No...that is not right.  Something is bent and/or goofed up.

You don't have to take off the tank to install the Raptor petcock - in fact on most bikes you can't take the tank off without first draining the tank and removing the stock petcock.  The back of the diaphragm casting catches on the frame on most bikes and prevents you from removing the tank.  You have to remove the fuel hoses, run a hose into a gas can, set the petcock to prime, and drain the tank.  When you remove the petcock there will be a few ounces of fuel that comes out....although if you have a sealed battery you can lay the bike on the right side and that will stop the flow of fuel when you take the petcock out.  I lay a piece of carpet on the floor and place the handlebar on a small stool to keep the turn signals from hitting the floor.  Then you can remove and replace the petcock.  If you don't lay the bike over -just have some rags to catch the fuel and quickly throw them outside if you are doing this in your house garage and the wife hates the smell of gasoline!  

When I first got my Savage......it only had 262 miles on it, and I didn't want to take it apart for anything.  As I worked on jetting the carb, changing the exhaust, putting on the Raptor petcock, etc., I soon found that taking the tank off was really only a 4-5 minute job (once I had switched to the Raptor petcock and didn't have to drain the tank to remove the stock petcock each time).  Three bolts and the seat is off, two screws and the rear tank mount is loose, disconnect the bottom of the speedometer cable, disconnect the fuel hose(s), set a towel on the frame behind the tank, pull the tank backwards and set the back end on the towel and tilt the front of the tank up to get to the wiring harness.  And this next step was the hardest for me to master......hold the front of the tank up with your right hand and reach up with your left hand and disconnect the wiring harness connector for the speedo with one hand!  You have to be able to push on the release clip and pull the connector apart at the same time.  I got pretty good at it after a few times....just like Fonzie could unsnap a lady's bra with just one hand!

The removal of the tank is much easier if the tank is low on fuel.

fuel line is 5/16
1/4 will go on, but very tight

Quote:


I think that when you pull the tank you're going to discover that one of the rubber cushions is missing and that that side of the tank is just sitting on the bare stud. When I bought my bike a few years ago the tank was sitting just about like you describe yours. PO lost the rubber cushion while working on the bike I'm guessing.

Dave and OldNSlow,

I have attempted to change the title away from Ryca Video to Dealer Prep, to more accurately reflect the nature of this post.

You were both correct about the rubber cushions that support the tank, both were missing. The problem with the tank bouncing around had nothing to do with the mishap.

As mentioned earlier the bike was a leftover 2013 and it wouldn't run on the day they chose to deliver it to me. One of their technicians cleaned the carburetor and for some reason he removed the tank and bitched up the paint on the frame.

There is also a pigtail for battery tender so I am now looking for recommendations for a maintenance free battery.

I am tired and will try to figure out how to post pictures tomorrow.

Is there a way to report unsatisfactory dealer workmanship to Suzuki?

Kenny G

It is 80 degrees here in North Texas today.

I got to ride the S40 and check out everything after the repairs. Everything appears to be functioning as advertised. No more buzzing noises.

Kenny G