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Fuel Tank Removal and Installation: Removal

WARNING: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.
  1. Relieve the fuel pressure. Refer to "FUEL SYSTEM PRESSURE RELIEF :".
  2. Disconnect the negative battery cable.
  3. Drain the fuel tank.
  4. Remove the front muffler. Refer to "MUFFLER - FRONT REMOVAL AND INSTALLATION :".
    Fig 1: Identifying Front Muffler
    G04102923Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube.
    Fig 2: Removing Fuel Tank Filler Tube Clamp At Fuel Tank
    G04102924Courtesy of SUZUKI OF AMERICA CORP.
  7. Disconnect the fuel line near the right front of the fuel tank.
    Fig 3: Disconnecting Fuel Line Near Right Front Of Fuel Tank
    G04102925Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the rear seat. Refer to "REAR SEAT CUSHION REMOVAL AND INSTALLATION :".
  9. Remove the fuel pump access cover.
    Fig 4: Removing Fuel Pump Access Cover
    G04102926Courtesy of SUZUKI OF AMERICA CORP.
  10. Disconnect the electrical connector at the fuel pump assembly.
  11. Disconnect the fuel line.
    Fig 5: Disconnecting Electrical Connector At Fuel Pump Assembly
    G04102927Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove the parking brake cables support bracket bolt.
  13. Remove the parking brake cables from the fuel tank.
    Fig 6: Removing Parking Brake Cables From Fuel Tank
    G04102928Courtesy of SUZUKI OF AMERICA CORP.
  14. Disconnect the fuel vapor line from the solenoid valve.
    Fig 7: Disconnecting Fuel Vapor Line From Solenoid Valve
    G04102929Courtesy of SUZUKI OF AMERICA CORP.
  15. Support the fuel tank.
  16. Remove the fuel tank strap retaining nuts.
  17. Remove the fuel tank strap.
  18. Carefully lower the fuel tank.
  19. Remove the fuel tank.
  20. Transfer any parts as needed.
    Fig 8: Supporting Fuel Tank
    G04102930Courtesy of SUZUKI OF AMERICA CORP.