Suzuki Burgman 400 - Service manual > Fuel Tank Removal and Installation

Removal

1) Remove the footboards. Refer to "Footboard Removal and Installation".

2) Remove the engine. Refer to "Engine Assembly Removal and Installation".

3) Remove the cushion lever mounting nut. Refer to "Rear Shock Absorber and Rear Shock Absorber Assembly Removal and Installation".

4) Remove the clamp.

5) Disconnect the fuel pump coupler.

6) Remove the fuel tank filler cap (1) and fuel drain tray (2) from the fuel inlet.

! CAUTION After removing the fuel drain tray (2), refit the fuel tank filler cap (1) to the fuel tank.

7) Remove the fuel tank by removing the bolts and bracket.

! CAUTION Keep away from fire or sparks since gasoline may leak.

Installation

Install the fuel tank in the reverse order of removal. Pay attention the following points:

• Tighten the fuel tank bolts.
• Remove the fuel filler cap (1) and install the fuel drain tray (2) on the fuel inlet.

! CAUTION After the fuel drain tray (2) has been fitted on the fuel tank, the fuel tank filler cap (1) should be fitted to the fuel tank.

• Clamp the wiring harness surely.

Fuel Pump Assembly Removal and Installation

Removal

1) Remove the front box. Refer to "Front Box Removal and Installation".

2) Loosen the fuel tank bolt and move the fuel tank rearward.

3) Disconnect the fuel hose (1).

! CAUTION After the fuel hose (1) has been disconnected, fit a blind plug to the opening.

4) Remove the fuel pump assembly (2).

! CAUTION When removing the fuel pump assembly, take care not to cause damage to it. If such a possibility is thought to exist, remove the fuel tank from the body. Refer to "Fuel Tank Removal and Installation".

! WARNING

• Use caution to minimize spillage of gasoline.
• Spilled gasoline should be wiped off immediately.
• Keep away from fire or spark.
• Work in a well-ventilated area.

Installation

Install the fuel tank assembly in the reverse order of removal. Pay attention the following points:

• Apply engine oil to the O-ring (1) and install the fuel tank.

! CAUTION Replace the fuel pump O-ring and fuel hose O-ring with the new ones.

• When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.

Tightening torque
Fuel pump mounting bolt: 10 N*m (1.0 kgf-m, 7.0 lb-ft)

• Tighten the fuel hose to the specified torque.

Tightening torque
Fuel hose mounting bolt (a): 10 N*m (1.0 kgf-m, 7.0 lb-ft)

Fuel Drain Tray and FTPC Valve Removal and Installation

Removal

1) Remove the front box. Refer to "Front Box Removal and Installation".

2) Remove the fuel tank filler cap (1) fuel drain tray (2) from the fuel tank.

! CAUTION After the fuel drain tray has been removed, the fuel cap should be fitted to the fuel tank.

3) Disconnect the hose (3) from the fuel cut valve.

4) Remove the FTPC valve (4) from the fuel drain tray.

Installation

Install the fuel drain tray and FTPC valve in the reverse order of removal. Pay attention the following points:

• The hose should be fitted on the black side "A" of the FTPC valve.

! CAUTION When installing fuel drain, care should be used not to cause tear or other damage.

Fuel Cut Valve Inspection

Inspect the fuel cut valve in the following procedures:

1) Remove the fuel cut valve. Refer to "Fuel Drain Tray and FTPC Valve Removal and Installation ".

2) Check for the following points and replace if any abnormal condition is found.

• With the fuel cut valve being immersed in kerosene (1), check that valve (2) operates smoothly and valve seat (3) contacts correctly.

• Using the special tool, apply vacuum to the fuel cut valve (4) and check that the gauge pointer moves correctly.

Special tool (A): 09917-47011 (Vacuum pump gauge)

• Check for resistance when the fuel cut valve is blown.

3) After finishing the fuel cut valve inspection, reinstall the fuel cut valve. Refer to "Fuel Drain Tray and FTPC Valve Removal and Installation".

FTPC Valve Inspection

Inspect the FTPC valve in the following procedures:

1) Remove the FTPC valve. Refer to "Fuel Drain Tray and FTPC Valve Removal and Installation ".

2) Check that air passes easily when blown from the orange paint side of the FTPC valve and that resistance exists when blown from the other side. If any abnormal condition exists, replace the valve with a new one.

1. Orange

3) After finishing the FTPC valve inspection, reinstall the FTPC valve. Refer to "Fuel Drain Tray and FTPC Valve Removal and Installation".

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