Mercedes Mullins
Draining the fuel tank of a Suzuki Hayabusa motorcycle can be done in several ways. The most common method involves using a fuel pump to drain the tank. This can be done by running the fuel line into a gas can and cycling the kill switch or priming the fuel pump by turning the key on and off. Another method is to remove the fuel pump and allow the fuel to flow out of the tank freely due to gravity. It is important to note that removing the fuel pump may not completely drain the tank, and some fuel will still be trapped inside. Other methods include using a rifle cleaning rod with a slotted tip to remove the last bit of fuel, letting the fuel evaporate by leaving the tank in the sun, or using a primer bulb with a fuel line to drain the tank. When performing any fuel tank maintenance, it is crucial to take safety precautions to avoid the risk of fire or explosion.
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What You'll Learn
Using a fuel pump
To drain your Hayabusa fuel tank using a fuel pump, follow these steps:
First, ensure your fuel tank is as empty as possible. This can be done by riding your bike until the tank is nearly empty, or by siphoning the fuel out. It is not necessary to completely empty the tank, but it should be close to empty to make it lighter and easier to handle.
Next, place a rag under the fuel pump to catch any drips. Disconnect the fuel feed hose from the small pipe on the fuel pump by squeezing the white tabs and pulling the black connector off. You may want to wrap the fuel pipe and nipples with plastic secured with a rubber band to prevent drips if the tank will be stored off the bike.
Then, tie the tank to an overhead structure with string and lift it to its full height. Push the surge hose and drain hose off the nipples at the lower right bottom corner of the fuel tank.
At this point, you can attach a clear plastic tube to the fuel supply line and place the other end into a gas can. Power cycle the key a few times to engage the pump and pump out the remaining fuel. Alternatively, you can hot-wire the pump to run without the engine on, but be careful not to let the fuel pump run dry for extended periods as this can be harmful.
Finally, lower the tank back to its original position and use a 4mm hex tool to remove the fuel tank bracket bolts from the back of the fuel tank.
Some Hayabusa owners have also suggested installing a switch to turn the pump on instead of turning the key on and off multiple times. This can be done by wiring terminals directly to the battery and then flipping a switch to activate the pump.
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Removing the fuel pump
To remove the fuel pump from your Hayabusa, you must first empty the fuel tank as much as possible. This can be done by running the bike until the tank is almost empty.
Once the tank is close to empty, you can then attempt to drain the remaining fuel. One method is to use a fuel pump. To do this, pull the fuel supply line from the pump, then attach a clear plastic tube running into a gas can. Power cycle the key a few times to engage the pump and pump out the remaining fuel. You can also use a primer bulb for an outboard boat motor, available at Walmart. This will get almost every drop out of the tank.
Another method is to use gravity to drain the tank. To do this, remove the original hose from the tank and fit a longer one. Connect the orange wire in the connector (unplugged) to +12V of the battery and the black wire to the ground. This will take about 90 seconds per gallon.
Alternatively, you can use a rifle cleaning rod with a slotted tip to remove the last bit of fuel. Put the end of a shop towel through the slot on the cleaning rod and swish it around in the tank to absorb the remaining fuel.
When working around gasoline, it is recommended to remove the battery to avoid the possibility of causing an electrical spark that could ignite spilled fuel or fuel vapors. To do this, remove the negative lead from the battery and wrap the lead in electrical tape to prevent accidental contact with gasoline.
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Hot-wiring the pump
To wire up the pump, it is recommended to only connect the power when the ignition is turned on. This can be done by connecting the power line (red) from the second fuel pump to the ignition. It is important to note that the power will only go to 12v+ for a few seconds when the key is turned on and then go dead until the bike starts.
For a 2000 Busa, one user replaced the old wire harness with a 2002 Busa wire harness, which included the ECU, Rotor, and wire harness. The new wire harness had a 4-wire male connector for the fuel pump, while the bike had a female connector with 2 wires. To resolve this, the user suggested cutting the male connector off the old injector harness and wiring it into the new harness.
Another user with a Gen 2 Hayabusa provided a wiring diagram for an aftermarket fuel pump:
- 85 to stock fuel pump hot wire
- 86 to stock fuel pump ground wire
- 30 to battery hot
- 87 to aftermarket pump hot
- Ground new fuel pump to battery
It is important to note that modifying the fuel pump wiring can be complex, and it may be easier to purchase the correct pump for your specific Hayabusa model.
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Siphoning
To siphon fuel from your Hayabusa, you will need a container to siphon into and a hose long enough to stretch from the inside of the gas tank to your container. Siphoning works by creating a vacuum that moves the fuel from a higher point to a lower point.
Firstly, find a gas can or another closed container to siphon the gas into. Any standard gas canister of sufficient volume will do, but remember that gasoline fumes can be hazardous, so avoid using an open container. You will also need a length or two of plastic tubing, with one long enough to reach deep into the gas tank and another shorter length that will reach just inside the tank. Clear tubing is preferable, as it allows you to see the gasoline moving through the tube.
Next, relieve the fuel pressure at the fuel rail and remove the fuel rail valve core at the nipple. Attach a hose with a clamp to the de-cored nipple. Place your gas can on the ground near the opening of the gas tank. Ensure that the hose remains lower than the level of gas in the tank, as this will allow the gas to flow naturally due to gravity.
You can also use a siphon pump, which can be purchased for a low price. These pumps have a variety of shapes and sizes, with some being automatic and others hand-powered. They function by creating suction in the middle of a length of tubing, pulling the liquid from one end of the tubing to the other.
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Removing the battery
Although it is not essential to remove the battery when draining the Hayabusa fuel tank, it is always safer to do so to avoid the possibility of causing an electrical spark that could ignite spilt fuel or fuel vapours.
- Remove the battery negative lead. This will disable the battery without removing it completely. However, this step should be approached with caution as a loose negative cable can easily get bumped or arch to a ground on the frame, causing a spark. If you choose to remove the negative cable, wrap the lead in electrical tape to prevent accidental contact with gasoline.
- Disconnect the ground cable from the battery. This will reduce the risk of a spark, as the only place the negative cable can arc to is the negative terminal of the battery.
- Remove the two bolts that fasten the pilot seat with a 6mm hex tool.
- Use a 4mm hex tool to remove the two screws and washers at the front of the battery.
- Carefully lift and remove the battery from its compartment.
By following these steps, you can safely remove the battery from your Hayabusa motorcycle when performing maintenance or repairs that involve handling gasoline or working near fuel vapours.
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Frequently asked questions
There are several methods to drain your Hayabusa fuel tank. You can use a rifle cleaning rod with a slotted tip to remove the last bits of fuel. You can also use gravity and remove the fuel pump to let the fuel flow out of the tank. Another method is to use the fuel pump by pulling the fuel supply line from the pump, attaching a clear plastic tube running into a gas can, and power cycling the key to engage the pump.
You will need a 6mm hex tool, a 4mm hex tool, a rag, and string.
It is recommended to remove the battery when working around gasoline drips and fumes to avoid the possibility of causing an electrical spark that could ignite the fuel.
Always double-check that the fuel feed hose coupling is securely attached to the fuel delivery pipe on the fuel pump. Pull on the connection three or more times to ensure the coupling is locked.
