Tank Removal

[Kanegs400]

I'm a total noob so bear with me. Recently bought a GS400 and have some issues to sort out. I have a Haynes manual but I'm not finding a section outlining tank removal. I need to drain it and just want it off to better inspect carbs air box etc. Any tips?? Also is there a better manual out there with better instruction?

Thanks for your help.

[RotaryRodder]

not sure on the small bikes, but even my old ninja was the same as my 1100.

there are 2 10mm bolts holding the back to the frame. undo those. lift if up a bit and disconnect the fuel line (and vaccum line if you have a vaccum petcock) from the petcock. lift the back up a bit more and slide it backwards. there are 2 pegs on the frame that go into a groove on the tank. Viola, tank is off.

[lord1234]

on my 400, there is only ONE bolt...i think it is a metric #12. You pull that out, and the tank should come off relatively easily. The petcock will come with the tank...disconnect all tubes from the petcock before hand...

Also, pm me your email address...and when I get around to scanning the factory service manual that is on the way to me, I will email you a copy...

[Kanegs400]

Thanks that's good info. It's easier than I thought. I'll try it tonight.

[kalessin]

The choices in repair manuals seem to be the Suzuki factory manual, the Haynes manuals (most but not all GS's covered) and Clymer (I think they have all the GS bikes covered).

The Haynes and Clymer manuals are infamous for their misprints. They get many things right, but sometimes a torque specification is off (snap!) or you have to figure out how things should line up in one of the tables.

Occasionally, they even get a procedure wrong; I needed to replace a drive cable in the powered driver's seat in my Volvo 850, and Haynes gave no instructions and insisted that I take it to a dealer instead of performing a simple repair that took about 45 minutes (clip some metal "hog rings", roll up the seat back cover, loosen some screws and bolts to release the cable, replace, tighten, zip-tie the seat cover back on).

If you're confused even by something in a repair guide, ask on the tech forum.

[Kanegs400]

I have the same problem with the Haynes manual for my Chevelle. I'v learned to use it as a guide more than anything. With bikes though I know nothing. As a result I'm hesitant to start taking things apart without very clear instruction. I'll figure it out I'm sure but slowly.

[Kanegs400]

Got it off.

Getting the tank off was a breeze. Thanks for your advice. Now I have a question about the petcock. It seems to be leaking a bit at the seam. Is there a fix for this or is it shot? One more question. I've drained the gas out of the tank. The bike sat for the winter with no stabilizer and the gas has a questionable color. Do or should I need to do anything to the inside of the tank before refilling?

[lord1234]

ok lets go down the list:

petcock leaking at the seam...is that the seam where it meets the tank? If that is what you mean then you could have a bad gasket...if so...you can do one of the following
a) order a new gasket form bike bandit...5 bucks or so
b) use the old gasket and some gasket sealer...
option A is definitely more ideal.

As far as the tank, take a look inside when the tank is empty...shine a flashlight in (don't use a MATCH!)...see if you see rust...if you don't...don't worry about it...if you see a little rust...don't worry about it...if you see a LOT of rust...go pick up some POR-15 and POR-15 the tank...a product called Kreem is also a valid alternative.

[Kanegs400]

Petcock

Not the seam at the tank. It's the sean between the two halves of the unit. As far as the inside of the tank it actually looks brand new. I see no rust whatsover.

[lord1234]

hmm....buy a new petcock?

[pmilano1]

Is there a cup on the bottom? Is it just the gasket (perhaps o-r) joining it to the assembly?


If so, it's $1.40 at BB.

[Kanegs400]

It's not leaking at the tank. At least not that I can see. It's the actual unit where the two halves join. I'm going to pick up some parts from my local bike shop so I might see what replacing it is worth. If it's not huge$$$ I'll just buy a new one and be done with it.