Shortcuts for plastic removal and installation - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 6 Old 03-26-2015, 08:08 PM Thread Starter
Junior Trooper
Join Date: Oct 2014
Posts: 3
Shortcuts for plastic removal and installation

Hours of miserable hours removing the plastic from my bike to lift the
gas tank, and then reinstalling the plastic, have motivated me to find
some shortcuts. This article applies to the 2012 DL650, but similar
shortcuts should work on all models.

- The main shortcut is to not remove the frame covers; removal is not

- Use of allen head sockets and a driver will make bolt removal
quick. You need only two.

Ignore the owner's manual, but see below.

After you get organized:

- Remove the seat.

- For each side, remove only the *front two* frame cover bolts. Unclip the
front end of the cover from the hook. When it's time to lift the tank,
the side covers will flex out enough that the tank will clear them.

- For each side, remove the three visible bolts on the side tank cover.

- Remove the two bolts on the top tank cover, and the plastic
fasteners toward the instrument panel. Unhook the cover as instructed
in the owners manual (not the service manual). Remove the top tank cover.

- Remove both bolts at the head of the tank. A very long socket
extension helps.

- Slide the side tank covers back and off the bike.

- On each side, remove the bolt that attaches the cowling to the

- Lift the tank.

This took me 22 minutes.

For reassembly, consider not installing the top tank cover at
all; it's only cosmetic. Then diassembly will go faster next time,
around 15 minutes for me.

Reverse the above steps, except for the part about the top tank cover
if you don't plan to reinstall it.

Reassembly, without the top tank cover, took me 14 minutes.

If you decide you want the top tank cover back on, this can be done at
the end. It took me about five minutes.

If I can find d-ring bolts to replace all of the hex bolts, this will
go even faster, maybe about 10 minutes in each direction.

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post #2 of 6 Old 03-26-2015, 08:39 PM
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Learning by doing can go a long way, as does common sense.

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post #3 of 6 Old 03-27-2015, 10:45 AM
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Join Date: Sep 2014
Location: New Brunswick, Canada
Posts: 69
I went yesterday through the process of removing the tank... It took me about an hour and half, including the side plastic panels, lots of time spending to figure it out. I think that next time as I know how the plastic is attached and as I know my way around, it will be much shorter. It is actually not too bad, I have seen and worked on worse...

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post #4 of 6 Old 03-27-2015, 12:43 PM
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Join Date: Apr 2014
Location: NE Alabama
Posts: 465
Thanks for detailing that. Just went through it recently and also removed the front part of the fairing to install the beak.
All the snappy, clippy crap about drove me crazy
And then there was the --Why in the would you use a 3mm head screw on a 6mm bolt and then factory torque it to a thousand ft/lbs? Still waiting to get the proper EZ Out to repair that.

2013 DL650
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1983 Seca 900
1980 XS 850 triple
1971 Dunstall Norton
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post #5 of 6 Old 03-28-2015, 11:51 AM
Join Date: Aug 2006
Location: Granbury, TX
Posts: 1,042
Also wanted to add, if you need to remove the right side frame cover, (for filling/flushing rear brake fluid) remove the battery, drill a hole in the battery box inline with the hidden phillips screw, this allows removing the screw and separating the frame cover from the rest of the black plastic trim that goes back to the tail. Easier for me then removing my top box and luggage rack. I don't take credit for this, I found it in another thread somewhere on this forum.


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post #6 of 6 Old 03-28-2015, 12:19 PM Thread Starter
Junior Trooper
Join Date: Oct 2014
Posts: 3

That's a great tip.

By the way, it it not necessary to remove the luggage rack in order to remove the frame covers. If you remove only the front bolts on the luggage rack, there will be enough play in the rack (that remains attached by the rear bolts) that you can easily slide the frame covers out and get them off the bike.


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