1999 2002 Suzuki Sv650 Tank Replacement 1999 2000 2001 2002 Repair Guide

Difficulty

Easy

Steps

Time Required

                          10 - 15 minutes

Sections

Seat
1 step
Tank
4 steps

Flags

Back1999-2002 Suzuki SV650
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Introduction

What you need

Step 1

              Seat

If you have frame covers below your seat, remove them by removing the 4 mm allen bolts holding them on. Use a 4 mm allen wrench to turn the screws counter-clockwise until they come off.
Once the frame covers are off, remove the 4 mm allen seat bolts on both sides of the seat. Use the 4 mm allen wrench to turn the screws counter-clockwise until they come off.
The bolt in the picture is not stock.
Lift the front of the seat, then pull it off the frame.

If you have frame covers below your seat, remove them by removing the 4 mm allen bolts holding them on. Use a 4 mm allen wrench to turn the screws counter-clockwise until they come off.

Once the frame covers are off, remove the 4 mm allen seat bolts on both sides of the seat. Use the 4 mm allen wrench to turn the screws counter-clockwise until they come off.

The bolt in the picture is not stock.

Lift the front of the seat, then pull it off the frame.

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Step 2

              Tank

Turn the two 4mm allen bolts in the front tank mounts counter-clockwise with an allen wrench until they come out.
The bolts shown in the picture are not stock.
Turn the two 12mm hex bolts in the tank’s hinge base counter-clockwise with a socket wrench or box end wrench until they come out.

Turn the two 4mm allen bolts in the front tank mounts counter-clockwise with an allen wrench until they come out.

The bolts shown in the picture are not stock.

Turn the two 12mm hex bolts in the tank’s hinge base counter-clockwise with a socket wrench or box end wrench until they come out.

Step 3

Disconnect the fuel level sensor connector, located near the tank hinge base. It will be a three wire connector and one side of the wire will be traceable to the underside of the tank.
Carefully lift the front of the tank to gain access to the hoses attached to the tank.
Do not lift the tank too much, or you risk damaging fuel lines, vacuum lines and spilling fuel.
There are small metal inserts that go into the front tank mounts. Make sure these do not fall out and get lost while working with the tank.

Disconnect the fuel level sensor connector, located near the tank hinge base. It will be a three wire connector and one side of the wire will be traceable to the underside of the tank.

Carefully lift the front of the tank to gain access to the hoses attached to the tank.

Do not lift the tank too much, or you risk damaging fuel lines, vacuum lines and spilling fuel.

There are small metal inserts that go into the front tank mounts. Make sure these do not fall out and get lost while working with the tank.

Step 4

Locate the petcock on the left underside of the tank. It hill have 2 hoses attached to it and will be next to the fuel level sensor.
Disconnect the vacuum hose from the petcock.
It is advisable to always remove this hose first to reduce the amount of fuel spilled.
Disconnect the fuel hose from the petcock
Disconnect the tank breather hose from the base of the tank.

Locate the petcock on the left underside of the tank. It hill have 2 hoses attached to it and will be next to the fuel level sensor.

Disconnect the vacuum hose from the petcock.

It is advisable to always remove this hose first to reduce the amount of fuel spilled.

Disconnect the fuel hose from the petcock

Disconnect the tank breather hose from the base of the tank.

Step 5

Carefully lift the tank up and off the frame of the bike, being sure that the fuel level sensor wire does not get caught in the frame.
When you set your tank aside, be mindful of the petcock hose fittings, especially the vacuum fitting on the bottom. These fittings can easily be broken by the weight of the tank and are costly to replace.

Carefully lift the tank up and off the frame of the bike, being sure that the fuel level sensor wire does not get caught in the frame.

When you set your tank aside, be mindful of the petcock hose fittings, especially the vacuum fitting on the bottom. These fittings can easily be broken by the weight of the tank and are costly to replace.

To reassemble your device, follow these instructions in reverse order.

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Author

                                      with 2 other contributors

                    Phillip Takahashi

Member since: 08/22/2011

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robert zuckerman - May 24, 2017

Thanks . I have to reassemble the tank and I was not the one that took it apart so this tutorial is quite helpful. I had to buy a new rubber tank mount as they fall off easily also.

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Introduction

What you need