Katerina Swanson
Removing the fuel tank from a Suzuki Savage motorcycle can be a tricky task. A common challenge is navigating the petcock past the frame. To remove the fuel tank successfully, several steps must be followed carefully. Firstly, undo all the hoses and disconnect the electrical connector and speedometer cable. Then, loosen the bolts holding the seat and the fuel tank in place. With the bolts removed, the tank can be carefully jiggled and pulled out.
Characteristics and Values Table for Removing a Suzuki Savage Fuel Tank
| Characteristics | Values |
|---|---|
| Step 1 | Remove the seat (3 bolts) |
| Step 2 | Remove the 2 bolts and bracket that hold the front of the seat on (rear of the gas tank) |
| Step 3 | The tank should now be loose |
| Step 4 | Pull the tank to the rear, jiggle it if the rubber pads are stiff |
| Step 5 | Unclip the electrical connector under the tank (use grease for easier removal in the future) |
| Step 6 | Unscrew the speedo cable from under the tank/speedo cluster (and lubricate) |
| Step 7 | The tank is now free to remove |
| Additional Notes | Ensure the hoses are undone and the petcock can pass the frame |
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What You'll Learn
Remove the seat
To remove the seat from a Suzuki Savage, you will need a 10mm socket wrench, and a ratchet will also help. There are two bolts on either side of the seat, underneath, that screw into the bike bracket and hold the seat in place. Remove both bolts, then push the seat forward a bit, lift from behind, and take it off.
If you want to remove the pillion pad, this is done with a single screw. To access the battery, you will need a Phillips-head and a flat-head screwdriver.
One source also suggests removing the right-side toolkit by unlocking/removing the cover, then removing the top screw and two bottom screws holding it in. Then, remove the triangular cover on the left side, just rear of the battery (this also has one top screw). Unscrew the left-side battery terminal, and push the battery out to the right.
Another source suggests removing the three bolts from the seat, and then the two bolts and bracket that hold the front of the seat on (rear of the gas tank).
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Loosen the front bracket
To loosen the front bracket of the Suzuki Savage fuel tank, you must first remove the seat. This is done by unscrewing three bolts that hold the seat in place. With the seat removed, you can access the front bracket of the fuel tank. The next step is to remove the two bolts that secure the bracket in place. These bolts will be located at the front of the seat, which is the rear of the gas tank. Once these bolts are removed, the tank will be loose. You can then pull the tank towards the rear of the bike.
It may be necessary to jiggle the tank to free it from the rubber pads it rests on. At this point, you can unclip the electrical connector located underneath the tank. Applying a small amount of di-electric grease will make it easier to remove the connector in the future. Now, you can unscrew the speedo cable, which is also located under the tank, in the speedo cluster. This is a good time to lubricate the cable.
The speedo cable may have a small washer or o-ring present, so be careful not to lose it during removal. With these steps completed, you will have successfully loosened and removed the front bracket of the fuel tank. The tank is now free to be fully removed from the motorcycle. It is important to follow these steps in a safe and controlled manner to avoid any damage to the motorcycle or injury to yourself. Always refer to a qualified mechanic or repair manual if you are unsure about any procedures.
Additionally, it is good practice to have a plan for safely disposing of any old fuel or materials from the tank and to take the necessary precautions when working with flammable liquids and materials. This process can be applied to most Suzuki Savage models, but there may be slight variations depending on the specific model and year of manufacture. It is always recommended to consult a service manual or seek advice from a Suzuki dealer or experienced mechanic before attempting any fuel tank removal or maintenance.
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Jiggle the tank
Removing the fuel tank from a Suzuki Savage motorcycle requires several steps, one of which involves jiggling the tank. Here is a detailed, step-by-step guide to this process:
First, remove the seat of the motorcycle. This entails taking out three bolts and then removing the two bolts and the bracket that hold the front of the seat in place (this is the rear of the gas tank). With these bolts and the bracket removed, the tank should be noticeably looser.
Next, pull the tank towards the rear of the motorcycle. You may need to jiggle the tank at this point if the rubber pads that it rests on are stiff. This is an important step to ensure that the tank can be moved and adjusted as needed. Jiggle the tank gently until it becomes easier to move and pull towards the rear.
Once the tank has been jiggled and pulled back, there are a few more steps to complete the removal process. Unclip the electrical connector located underneath the tank, and apply a small amount of di-electric grease to make future removals easier. Finally, unscrew the speedo cable from under the tank/speedo cluster, and lubricate the cable. With these steps completed, the fuel tank will be fully removed.
By following these steps, particularly the crucial step of jiggling the tank to loosen it, anyone can successfully remove the fuel tank from a Suzuki Savage motorcycle. This process ensures that the tank is safely and effectively removed for any necessary repairs or maintenance.
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Unclip the electrical connector
To unclip the electrical connector, first locate it under the fuel tank. You may need to pull the tank towards the rear to access it. Once you have located the electrical connector, apply a small amount of di-electric grease to it. This will make it easier to unclip and will also help with future removal. Next, using your fingers or a small tool, gently pry the connector apart. It should unclip with a small amount of force. Be careful not to damage the connector or any surrounding components. Once the electrical connector is unclipped, set it aside safely so that it does not accidentally come into contact with any metal parts or cause an electrical short. Now that the electrical connector has been successfully unclipped, you can proceed with the next steps of removing the Suzuki Savage fuel tank.
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Unscrew the speedo cable
To remove the fuel tank of a Suzuki Savage, you will need to unscrew the speedo cable from under the tank. This is the final step of the fuel tank removal process, after disconnecting the electrical connector.
Firstly, remove the seat of the bike. There is one hex bolt at the rear and a 10mm bolt on each side. This will expose two more 10mm bolts and a hold-down bolt at the rear of the tank. Remove these two bolts.
Now, disconnect the fuel line to the carb and a second breather line that attaches to the fuel selector switch. It is recommended to drain the tank from the hose into a container by putting the fuel selector on "prime".
With the tank drained, pull the tank rearward and slightly to the rider's left side in a wiggling motion. The front of the tank has two receiver slots that wedge onto rubber donuts. Once the tank comes rearward a bit, you can pull up in a firm motion, and the tank will come free.
Now, you can unscrew the speedo cable. Have a helper hold the tank sideways so you can reach up and unscrew the speedo cable and disconnect the gauge electrical connector. You may want to lubricate your cable at this point. There is a small washer or o-ring that can go missing, so be careful not to drop it.
The tank will now be free to remove fully.
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Frequently asked questions
First, remove the seat (3 bolts) and the 2 bolts and bracket that hold the front of the seat (rear of the gas tank). Pull the tank to the rear, jiggling it if needed. Then, unclip the electrical connector and unscrew the speedo cable. The tank will now be free to remove fully.
Before beginning the removal process, ensure all hoses are undone. You may also want to apply a dab of di-electric grease to the electrical connector for easier removal.
After removing the fuel tank, you should lubricate the speedo cable.
