Bandit 1200 Fuel Tank Removal

I've covered this elsewhere but thought I'd write it up as its own procedure for ease of searching.

Tools & Supplies Required

• 10mm socket
• Small Phillips screwdriver
• Long needle-nose pliers, Long angle pliers
• wood 2x4
• Rag
• Milk crate or sturdy box

This should take no more than 15 minutes. Begin with bike on center stand. Remove seat, then unscrew and remove fuel petcock lever. Lever can be in any position except PRI.

Remove the 2 10mm bolts and the base of the tank, and the rubber mounts underneath the 2 metal tabs.

Pull the tank about 2" toward the rear of the bike, then lift the front and move it forward again. There is a metal tab on the front of the tank that sbould rest on the front rubber tank mount.

Prop the rear of the tank up with the 2x4 on the low height.

With the tank in this position, remove the overflow hose on the left side by moving the clamp down the hose about an inch, and pulling the hose off the tank fitting.

On the right side, unclip the fuel sending unit and pull off the vent hose next to it.

Move the 2x4 to the tall height.

Put the rag under the fuel petcock to catch any gas that comes out.

Remove the 2 hoses from the petcock. The smaller hose is a vacuum hose which can be pulled off. The large hose is the fuel hose. Unclamp it with the long pliers and move the clamp about an inch down the fuel hose.

Pull the fuel hose off and be ready for some gas to come out.

Finally, lift off the tank and place it on the box or milk crate, making sure no weight is on the fuel petcock or hose fittings under the tank.

Reinstallation is the reverse. I couldn't find torque specs for the tank bolts. Finger-tight plus a quarter turn should be plenty, do not over-tighten.