LTZ400 Gas Tank Removal

Question:

I can't figure out how to remove the LTZ400 gas tank to change the spark plug.  Can you please help. {Jeremy, AL  2005 Suzuki LTZ400 QuadSport with aftermarket pipes}

Answer:

The first thing you need to do is turn the fuel petcock to off and remove the fuel line from the valve.  Next, remove the plastics that are covering the tank.  They are held on by plastic body clips.  The body clips are like plastic rivets.  Use a small regular screwdriver and lightly pry up on the center heads to loosen them.  They are only plastic, so be careful.  

In the microfiche diagram of the front fenders below, the body clip is number 16. It is holding down the center fender body piece. After the clip is out this piece should lift out.

Suzuki LT-Z400 Quad Sport Front Fenders


Next, remove the clips from the side covers, number 3. Check for another bolt or clip. Although it is not shown in this schematic, it may have a bolt or clip through the upper, forward edge that is shared with another body piece (front fender).

Suzuki LT-Z400 Quad Sport Side Covers

Once the plastic body panels have been removed, you will be able to move the air cleaner inlet duct cover, number 19 in the diagram of the fuel tank below, out of the way to access the 2 bolts that hold down the gas tank, located at the rear of the tank. Remove the bolts, number 13.

You probably have to remove the screw and seat hook washer, numbers 8 and 10, also. I can't be sure from the diagram. It will be clear to you when you get to this point, I am sure. Don't lose the washer.

Now, pull the tank up just a half an inch and then back two inches.  This will pull it out of the front cushion, number 5. 

Suzuki LTZ400 Gas Tank


Upon reinstallation of your LTZ400 gas tank, you may need to replace some of the plastic body clips. If they break, this is not necessarily because you did anything wrong. Its not your fault, they are fragile. The part number for them is 09409-07333, Clip.  You may want to order a bag of them from your dealer.



The micro fiche diagram images above were borrowed from honda-dealer.com. If you need to see how part of your bike is assembled or want to find an OEM number or estimated price for a part you can always check their website. It is free to use.


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