Katerina Swanson
Removing the fuel tank from a Suzuki S40 motorcycle is a complex process that requires careful attention to detail. To begin, one must remove the seat and tank bolts, ensuring the fuel valve is on. Next, the large and small gas lines must be disconnected, and the tank drained of fuel. With the fuel lines and wiring harness disconnected, the tank can be carefully lifted and removed from the bike. It is important to note that different models may have slight variations in the process, such as California models with an extra hose to disconnect. Additionally, there may be breather tubes under the tank that require careful handling.
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What You'll Learn
Remove the rear seat
To remove the rear seat of a Suzuki S40, follow these steps:
First, remove the seat. There are two bolts at the front of the seat that need to be unscrewed. These are the only things holding the seat in place, so once they are removed, the seat can be lifted up and out. Next, you will need to drain the fuel tank. Make sure the Fuel Valve is in the "on" position, then move the valve to the "prime" position to drain the gas. Now, disconnect the fuel lines. There is a large gas line on the left side of the carb that needs to be removed, as well as a small gas line on the right side. With the fuel lines disconnected, you can now lift the rear of the tank up and pull back to remove it.
It is important to note that there may be some difficulty in breaking the seal between the tank and the rubber grommet type rings that hold it in place with the frame. You may need to push, wiggle, and pull the tank to break this seal. Additionally, there are breather tubes under the tank that you should be careful not to damage, as they can be difficult to reattach.
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Disconnect the fuel line
Disconnecting the fuel line on your Suzuki S40 is a crucial step before removing the fuel tank. Here is a detailed guide to help you with the process:
Firstly, locate the fuel line on the left side of the tank. This is the "Prime" gas line, which needs to be removed first. Make sure that the Fuel Valve is in the "On" position to ensure that you can effectively drain the gas from the tank.
Next, you need to drain the gas from the tank. To do this, move the Fuel Valve to the "Prime" position. This will allow the gasoline to flow out of the tank through the "Prime" gas line. It is important to safely collect and dispose of the drained gasoline, as it is a flammable substance.
Once the tank is empty, you can now remove the "Prime" gas line. Carefully disconnect the fuel line from the left side of the carburetor. This may require some wiggling and gentle force to detach it completely. Ensure that you do not damage the surrounding components or the fuel line itself.
After disconnecting the "Prime" gas line, there may be an additional small gas line present on the right side of the carburetor. If so, proceed to remove this line as well. Ensure that all fuel lines are disconnected before proceeding to remove the fuel tank.
Now that the fuel lines are disconnected, you can continue with the process of removing the fuel tank. Refer to your Suzuki S40 manual or seek additional instructions for the next steps to safely remove the fuel tank. Remember to exercise caution and follow proper safety procedures when working with gasoline and motorcycle components.
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Drain the gas tank
To drain the gas tank of your Suzuki S40, you can use a siphoning method. This can be done by purchasing an inexpensive pump siphon or using a hose and manually sucking the gas out.
If you choose to use a pump siphon, follow these steps:
- Purchase a pump siphon from a hardware store or auto-parts store.
- Connect the pump siphon to the gas tank and a gas can.
- Prime the line by squeezing the bulb once, and the siphon will start flowing automatically.
If you prefer to use a hose, you can follow these steps:
- Obtain a clear vinyl hose with a diameter of 3/8 inches and cut it to a length of 5 feet.
- Insert one end of the hose into the gas tank as deep as possible, and place the other end into a gas can.
- Take a rag or washcloth and push it into the filler hole to create a seal around the hose.
- Blow into the short hose to pressurize the tank and start the siphoning process. Alternatively, you can use your mouth to suck on the hose, but be careful to avoid ingesting any gasoline.
It is important to note that gasoline is highly volatile, so exercise caution during the draining process to avoid any potential hazards.
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Break the seal with the rubber grommet
To break the seal with the rubber grommet, you must first remove the seat and the tank bolts as per the Owner's Manual instructions. Ensure the Fuel Valve is in the "On" position. Next, remove the gas lines, starting with the large "Prime" gas line on the left side of the carb, and then the small gas line on the right side.
Now, you can begin to break the seal. Push, wiggle, and move the tank around to loosen it from the rubber grommet type rings that hold it in place with the frame. There are two rubber grommets that extend perpendicularly from the frame under the tank, sliding into groves on the tank, which may be stuck to the tank, making it difficult to remove. Once the seal is broken, pull the tank back and up, with a slight bias to the left, to remove it.
It is important to note that, even when the tank comes free, there are still some connections to be disconnected, such as the harness and the speedo cable. Additionally, remember to drain the tank before beginning the process of removing the fuel lines to avoid spillage.
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Lift the tank
To lift the tank, you will need to first remove the seat and the tank bolts per the owner's manual instructions. Make sure the fuel valve is set to the "on" position. Next, remove the fuel lines on the left side of the tank. For the Suzuki S40, disconnect the large gas line where it goes into the left side of the carb—this is the "'prime'" gas line. Then, remove the small gas line from the right side of the carb.
Now, you can start to lift the tank. Push the tank around and wiggle it to break the seal it has with the rubber grommet type rings that hold it in place with the frame. Be careful, as there are breather tubes under the tank, and these can be difficult to put back on depending on their length. Once the seal is broken, carefully lift the tank up and back to remove it from the bike.
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Frequently asked questions
Here are the steps to remove the fuel tank from a Suzuki S40:
- Remove the seat.
- Remove the bolts holding the tank in place.
- Disconnect the fuel lines and drain the tank.
- Lift the tank up and back to remove it from the bike.
Yes, it is important to drain the fuel tank before removing it. Make sure the Fuel Valve is set to the "On" or Prime position to drain the gas from the tank.
If the fuel tank is stuck, try wiggling it or pushing it around to break the seal with the rubber grommet type rings that hold it in place with the frame. You may also need to disconnect any wiring harnesses or fuel lines that are still attached.
