Saturday, June 25, 2011

GS500 Gas Tank Removal

The GS500 gas tank can easily be removed in just a few minutes with minimal tools. The tank does not need to be empty to remove it. The tank needs to be removed to clean or replace the air filter, check or adjust the valves, or adjust or clean the carburetors. This post will document removing the tank on a 2007 Suzuki GS500F with the fairing already removed. On some GS500s, the side panels may also need to be removed.

GS500 Gas Tank Removal

The tools I used:
GS500 Gas Tank Removal

1) Put the motorcycle on the center stand to make it more stable.
GS500 Gas Tank Removal

2) Remove the seat. Turn the key while lifting up on the rear of the seat.
GS500 Gas Tank Removal
GS500 Gas Tank Removal

Seat removed:
GS500 Gas Tank Removal

3) Ensure the fuel petcock is turned on and the fuel cover on the tank is secure. The actual fuel tap is under the tank and will be turned off in step 6.
GS500 Gas Tank Removal

4) Use the 12mm socket and ratchet to remove the two bolts, each one securing either side of the tank.
GS500 Gas Tank Removal
5) Gently lift up on the rear of the tank and slip a piece of wood to support it.
GS500 Gas Tank Removal
6) From the right side of the bike looking towards the left, the fuel tap is visible under the tank.
GS500 Gas Tank Removal
Use the flat-bladed screwdriver to turn it to the off position which is horizontal.
GS500 Gas Tank Removal
7) Using the pliers, loosen the two hose clamps and remove the fuel hoses from the fuel tap. Make a note of which hose goes where. I used a zip tie to mark one side.
GS500 Gas Tank Removal
Have a rag handy to catch the couple drips of gas that will be in the hoses.
GS500 Gas Tank Removal

8) Remove the water drain hose
GS500 Gas Tank Removal
All three hoses removed:
GS500 Gas Tank Removal
Another shot of the three hoses.
GS500 Gas Tank Removal
9) Now that the tank is free of the hoses, lift up on the rear of the tank and pull towards the back of the bike slightly. The tank should come free easily. Place in a safe place.
GS500 Gas Tank Removal
10) Installation is the reverse of removal. I found it easiest to put the rear fuel hose on first, and then the front. They are quite close together and make for a tight fit.
GS500 Gas Tank Removal
11) Remember to turn the fuel tap back to the on or vertical position.
12) There is no specified torque for the two rear 12mm bolts.

Other GS500 Guides/Howtos:

1 comment: