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Fuel Tank 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. Remove the rear seat.
  4. Drain the fuel tank.
  5. Remove the front muffler. Refer to MUFFLER - FRONT REMOVAL .
  6. Remove the nuts with fuel tank shield.
    Fig 1: Identifying Fuel Tank Shield
    G04719121Courtesy of SUZUKI OF AMERICA CORP.
  7. Remove the fuel filter. Refer to Fuel Filter Removal .
  8. Remove the fuel tank filter tube clamp at the fuel tank.
  9. Disconnect the fuel tank filler tube.
  10. Disconnect the fuel vapor line near the fuel tank filler tube.
  11. Disconnect the fuel pump harness connector.
    Fig 2: Identifying Fuel Pump Harness Connector
    G04719122Courtesy of SUZUKI OF AMERICA CORP.
  12. Disconnect the fuel inlet line and the fuel return line near the right front of the fuel tank.
    Fig 3: Identifying Fuel Inlet Line And Fuel Return Line Near Right Front Of Fuel Tank
    G04719123Courtesy of SUZUKI OF AMERICA CORP.
  13. Support the fuel tank.
  14. Remove the fuel tank strap retaining nuts.
  15. Remove the fuel tank strap.
  16. Carefully lower the fuel tank.
  17. Remove the fuel tank.
  18. Transfer any parts as needed.
    Fig 4: Identifying Fuel Tank Strap
    G04719124Courtesy of SUZUKI OF AMERICA CORP.
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