Tank Removal

And now for a break from chain maintenance... occasionally other maintenance is necessary as well. On the Bandit it's necessary to remove the tank for many tune-up services including valve adjustment and carburetor sychronization.

Time

15 minutes

Materials

• 2x4 or wood block
• pliars
• needlenose pliars
• small phillps screwdriver
• 10mm socket
• rag
• milk crate

Note, it's easiest to do this when there isn't much gas in the tank.

Steps

• Remove the seat
• Remove the fuel valve handle with a phillips screwdriver
  



• Remove the two bolts securing the tank with a 10mm socket

• Remove the rubber mounts underneath the two rear tabs on the tank

• Pull the tank about 1" toward the back of the motorcycle, then lift the front and rest the front tab on top of the rubber mount at the front of the frame. When reinstalling the tank, note that this tab slides underneath the rubber mount.
  

• put the 2x4 under the two tabs at the rear of the tank.

• Disconnect the fuel sensor on the right side of the bike by pressing in on the lower end.
  

• Disconnect the overflow hose behind the fuel sensor

• On the left side of the bike, use the regular pliars to move the hose clamp down the braided hose a few inches, then disconnect the braided hose.

• At this point the tank can be raised a bit more. Cover the engine with a rag to catch any gas that leaks after the next step.

• From the right side of the bike, remove the vacuum hose from the fuel valve. Then use the needlenose pliars to loosen the hose clamp and disconnect the fuel hose. Fuel may drip from the fuel hose and/or fuel valve.
  

• Tank may now be removed. Store it on a milk crate to avoid putting any pressure on the fuel valve. The seal is prone to leaking.
  

• To reinstall the tank, reverse steps above. The two bolts securing the tank do not need to be very tight at all--finger tight plus half-turn at most.