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Message started by timhonse on 03/19/10 at 09:41:31

Title: Gas Tank Removal help
Post by timhonse on 03/19/10 at 09:41:31

I am trying to change the spark plug for the first time on my '97 Savage. I have the Clymer manual, but I am stuck on getting the gas tank off. This is one topic on the Technical Docs board that is a "broken link," so any help or guidance would be greatly appreciated.

According to the manual, there are just two bolts on the back of the tank to remove, which I have done. I have disconnected all the appropriate lines (fuel, vacuum, etc.). It says to slide the tank back and then pull up, but I can just barely get it to budge. I can move it back maybe an inch, and no more.

It sounds like it is catching on something. Is there another bolt I am missing somewhere? Is there a trick to "sliding it back" that I am doing wrong? Please help!

Title: Re: Gas Tank Removal help
Post by prechermike on 03/19/10 at 09:46:39

I have taken the tank off a couple of times, as I recall you need to slide it back and lift up on the rear of the tank as well. There are a couple of nubs that have rubber bumpers on them under the tank, on the sides of the frame. Also, there are some connectors under the tank, the conections for the speedo lights, just a plug. Sometimes the petcock gets hung up and you need to wiggle the tank around to get it off.

Basically, you are probably doing it right, just need a little wiggle in your walk! ;)

Title: Re: Gas Tank Removal help
Post by timhonse on 03/19/10 at 09:54:16

Alright, thanks for the assurance. Yeah, I noticed the petcock is getting in the way. I just didn't want to break something by wiggling too hard. I'll try again tonight and see how it goes. Thanks!

Title: Re: Gas Tank Removal help
Post by jabman on 03/19/10 at 09:56:42

yep the stock petcock gets in the way ive removed the tank once without removing it the other times i chickened out and drained the tank

Title: Re: Gas Tank Removal help
Post by timhonse on 03/19/10 at 10:10:45

I may do that. I don't see that in the manual. Without looking at the bike, it seems like it would be just as simple as turning the petcock to ON to drain it, then unbolting the petcock from the tank. Am I missing anything?

Title: Re: Gas Tank Removal help
Post by prechermike on 03/19/10 at 10:12:45

7865616463627F690C0 wrote:

That's right, run a hose into a tank or can to catch the gas though ;) I changed my petcock to the raptor and don't have any trouble taking the tank off.

Title: Re: Gas Tank Removal help
Post by LostArtist on 03/19/10 at 10:16:17

yeah removing the tank gets kinda funny there, just keep working at.

Title: Re: Gas Tank Removal help
Post by RidgeRunner13 on 03/19/10 at 10:31:16

Did you disconnect the speedo cable? 8-)

Title: Re: Gas Tank Removal help
Post by verslagen1 on 03/19/10 at 10:36:09

To drain the tank, turn to prime.

lift the rear of the tank and wiggle to the left.

If you're the kind that can't bear to scratch your frame, take the petcock off. Although, I thought that is a tuff route too. I'd just slip a piece of cardboard in there if that was your inclination.

Otherwise wiggle it about, 1st time tuffest.

BTW, some tanks just won't and you might have to remove the petcock.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1256079122/11#10

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1191899985/0#0

Title: Re: Gas Tank Removal help
Post by spacepirates on 03/19/10 at 12:02:24

give in and remove the petcock. I had another forum member, BurnPgh, help me get the tank off the first time and we had to take the petcock off.

it is a pain, and takes forever to drain all the fuel out, but it is a lot easier to manage once you have.

besides, if you have to drain the tank, it gives you a good incentive to ride around and use gas so you have less to drain!

Title: Re: Gas Tank Removal help
Post by wolfmrp on 03/19/10 at 15:13:19

I took mine off a couple of weeks ago and I had to tilt it sideways to the left(the petcock side). It came off but was a pain. It was almost as hard to get it back on. :(

Title: Re: Gas Tank Removal help
Post by timhonse on 03/19/10 at 16:40:06

OK, good news and bad news.

The good news is I took the petcock off without any trouble and within no time I had the gas tank off, spark plug changed and everything put back together. After seeing how it all fits together, I can't imagine getting it off without getting the petcock out of the way.

The bad news is a cold spell just returned to Kansas City so it's going to be a few more days before I get to take the new spark plug for a spin.

Also, I did learn one thing that might be useful for another Savage beginner out there: the Clymer manual says to use a 17mm spark plug wrench but neither the 17mm that I just bought, nor the standard 5/8in would work. So, I ran to the store for an 18mm socket which did the trick.

Title: Re: Gas Tank Removal help
Post by kickstartmyheart on 03/30/10 at 08:51:09

you can get the tank off with out removing the petcock just take of the fuel lines loose hardware and jiggle it off... when you get the tank off the frame loosen the speedo cable and disconnect the electrical stuff and your good... i have manage to do this over and over. it just takes some finesse....

Title: Re: Gas Tank Removal help
Post by justin_o_guy2 on 03/30/10 at 14:28:53

Do the Head Cover Mod. No more gas tank hassles to get that plug out.

Title: Re: Gas Tank Removal help
Post by kickstartmyheart on 03/30/10 at 20:04:17

head cover mod is awesome... works like a charm

Title: Re: Gas Tank Removal help
Post by justin_o_guy2 on 03/31/10 at 07:06:32

& remember to blow the dirt out of the hole before pulling the plug.

Title: Re: Gas Tank Removal help
Post by MaxMayhem on 04/12/10 at 21:15:44

Yeah, my first post.

I've been reading this forum since I purchased my '07 LS650 a couple of months ago.

I did the sparkplug mod yesterday.

I also cut out a 10mm square notch from the inside front corner of the cover, as it kept stopping when being swung open.

I was lucky enough that the tank lifted up pretty easily (I had disconnected the vapor line & fuel line) and I jiggled the tank to the left until the petcock was clear then just put the tank back on top of the frame.
Not sure why people have needed to disconnect the speedo cable? (guess older models have slightly different setups.)

That left more than enough clearance to get at the plug and remove the rear cover bolt for the mod.

Getting the tank back in place however did take about 10mins of jiggling and swearing to get back into place.

And after doing all this, my tool kit that was in the bike when I purchased it, did not have the sparkplug socket. Got one arriving tomorrow morning (11/16" deep socket from powerbuilt)

Thanks to all the experienced members who post these great tips.
I am totally inept at mechanics, but even I reckon I can do most of the mods I've seen here thanks to the pictures. Pity most of the threads have had the pictures removed, but I saw a post someone mentioned about the forum hosts limitations, and habit of moving/removing parts of the forum at whim, so if I really need pictures to grasp a particular concept, I will ask.

Title: Re: Gas Tank Removal help
Post by LostArtist on 04/12/10 at 21:35:43

does 11/16 = 18 mm???

Title: Re: Gas Tank Removal help
Post by verslagen1 on 04/12/10 at 22:28:22

7D5E4245704345584245310 wrote:

does 11/16 = 18 mm???

18mm = .709"
11/16" = 17.46mm

Title: Re: Gas Tank Removal help
Post by Rocco on 04/13/10 at 08:01:53

i replaced my flasher relay(right side under tank) with a big ol' electrical one, so if u think gettin the tank off now is a pain, put a relay that's probably 10 times bigger then the og....lol it makes things a little harder!

when i bought it i thought "this thing is gonna hold up great, it looks like it's for diesels" lol

Title: Re: Gas Tank Removal help
Post by MaxMayhem on 04/13/10 at 19:15:12

4665797E4B787E63797E0A0 wrote:

does 11/16 = 18 mm???

As I now am completely aware no it does not.
The 11/16" was too small by about 1mm all around the od of the plug.

A sales rep who comes into my work is a bit of a m/c fan, and went back to his place to get me a 18mm deep socket.

But as is typical of my luck with engines etc, he bought back a 1/2" drive socket, and I had to go thru about 3 different sets in our shop till I got an adaptor that wasn't too wide so I could turn the darn thing.

All the ones I already had were 3/8".

Finally got out the plug that was in the bike when I brought it, it was a NGK d7ea??? I put in a NGK dpr8ea-9.

Would the d7ea have caused anything bad to happen that I should take a look at?

Now I need to go and order a 18mm deep socket as the rep wants his one back.

Title: Re: Gas Tank Removal help
Post by justin_o_guy2 on 04/14/10 at 01:53:40

A`lawn & garden store will have a plug wrench for small engines, somewhere in the$3.00 to $5.00 range, Lowes has them, last I looked. I didnt check to see if theyll fit our plugs, but they sure looked a lot like the one in the tool kit.