Tech question. Virago 535

How do you cut the fuel supply to remove the fuel tank please?

A friend has just been on the phone asking because they're trying to
replace the battery on their daughter's one. They've pulled the tank up
and can see a fat pipe and a thin pipe going up directly into the tank,
but there's no visible method of cutting the fuel supply before
removing either pipe. It has an electrically operated reserve switch on
the right handlebar too.

It's a 96 bike if that makes any difference.

Cheers.

--
Lozzo
Suzuki SV650S K5
Honda CBR600 FW trackbike
Yamaha SR250 Spazz-Trakka
Suzuki GSXR750 L
Suzuki TS50X
Suzuki TS50X

 

I don't think you can?

I *think* you can change the battery with the tank pulled out of the
way but it's been a while now.

I think when I was doing any of that on hers [1] I siphoned the top
tank and then did the same through the fuel gauge / sender hole on the
bottom one?

From memory that just shuts off the fuel pump when the level reaches
reserve. You then switch it to reserve to re-start it again.
All the best ..

T i m

[1] The second time we made sure it was empty ;-)

 

Brilliant, I've passed that one, thanks.

--
Lozzo
Suzuki SV650S K5
Honda CBR600 FW trackbike
Yamaha SR250 Spazz-Trakka
Suzuki GSXR750 L
Suzuki TS50X
Suzuki TS50X

 

NP

FWIW (and in case they get stuck and get back to you), on the early
bikes the tank was simply under the saddle, with a dummy in the std
tank position.

Later bikes had a (2G?) tank under the saddle and an extra (1G?) tank
in the std position, coupled to the lower tank by two rubber hoses
(one larger one for 'fill' and a smaller one for 'breathe').

If the top tank was nearly empty and if you freed the hoses from their
clips on the frame, I think there was just enough room / slack to part
the hoses and pull the battery up from in-between (two person job).

If the fuel level was down to the lower tank, one or both the hoses
could be removed from the upper tank (spring type jubilee clips)
allowing the hoses to be manipulated easier.

The missus actually went from her KH125 to an early XV535 that had
been modified with a modded_later_top_tank (std exit holes blocked up
an a traditional tap / hose fitted) but they were treated like two
separate tanks. ie. You would use up the lower tank then drain the top
tank into the bottom one (like filling it from a plumbed_in Jerry can
etc).

I put it back to stock before selling it and getting her the later
model (then the XV750). ;-)

All the best ..

T i m

 

As others have mentioned, you cant on the upper tank, it feeds fuel to the
lower tank through the big hose.

I managed to get the upper tank off when it was half full a couple of times,
i managed the pull on the hoses enough to tip the tank forwards to theres no
fuel at the hose outlets, then undid them and passed the tank to a helper
who held it pointing downwards, but not too far so the fuel came out the
cap's breather... but if the bikes been ridden more than about 40 miles
since last re-fueling, the top tank will be empty anyways, it only holds
about 4 litres if that.

On the early models, when the fuel ran low the fuel pump was shut off to
simulate running out of petrol, flicking the switch allowed the pump to run
again,
the later models with the twin tanks, the switch operates a solenoid at the
tap in the bottom tank, changing to reserve as you would manualy but doing
it electricaly... but the solenoid is a known weakness on that bike,

If it's not switched to reserve that often, then the solenoid will likely
jam in the normal position when you need it the most, most xv535's will have
had the solenoid unit replaced at least once it their life time... a good
clout on the actual unit when the switch is in reserve will usually get it
to change over when your stuck at the side of the road, but it's a bastard
to get at in the first place, and then theres the risk of it sticking in the
reserve position after it's switched over.

 

What is this upper tank of which you speak? New fangled nonsense, I'll be
bound.