Author Topic: Gas Tank? (Read 4625 times)

Honest-Al · « **on:** September 19, 2007, 05:34:46 AM »

I recently got a new 1200 "Final Edition" Bandit. Great bike!!
I have a shop manual on order for it but I want to take off the tank to check the air cleaner.
This bike is a 1250 with the old motor in it. It does not have a petcock.
What is the trick of getting the tank off without gas all over the floor?

Red01 · « **Reply #1 on:** September 19, 2007, 12:24:20 PM »

No petcock???
Never heard of that before! There should be one on the left, between the carb and the engine. If the handle is broken off, you should see a small D shaped shaft sticking out of the petcock and it'll be buried back in there a little ways.

The petcock should be pointed to "ON" or "RES" before pulling the fuel hose off the tank. In either of these positions, it won't leak fuel as long as the engine isn't running or the petcock diaphragm defective. In "PRI" it will flow fuel anytime.

pmackie · « **Reply #2 on:** September 19, 2007, 12:44:53 PM »

Like Red01 says, there MUST be a petcock there, only you don't normally open/close it, as they are vacuum operated.

So...
1. Make sure the petcock is positioned to "on" or "res".
2. Take out the rear tank bolts. Watch for the rubber washers, 2 per bolt.
3. Remove the petcock handle (assuming it IS there). #2 Phillips IIRC.
4. Disconnect the vacuum line and fuel line from the petcock. It's easier if you lift the tank slightly.
5. Remove the 2 rubber lines from the Right Rear bottom of the tank. 1 is a drain from the filler the other is a tank vent hose.
6. Slide the tank back slightly, to free it from the front slide bracket, then lift it off.

This is the proceedure for the 2nd Gen, but I'm 99% certain the 2.5 Gen is the same. (and likely the 3rd Gen as well)

Red01 · « **Reply #3 on:** September 19, 2007, 02:45:04 PM »

The proceedure for the 1G is the same, except the side cowls have a spike on each side that must be pulled from the rubber grommet in the rear of the tank. Pop these babies out before lifting the tank.

600's would be the same, except 1G and early 2G's with no gas gauge won't have an electric connector to unplug.

Honest-Al · « **Reply #4 on:** September 20, 2007, 04:10:36 AM »

I hate to tell you but I took the two bolts out of the rear of the tank and raised it up to have a peek and there is NO petcock!!
There are two rubber hoses going into the tank and a wire(fuel guage?)
Maybe this is the way the 1250 is.
Rememeber, this is Final Edition, so it probably is different from yours.
How does the 1250 tank come off?

H2RICK · « **Reply #5 on:** September 23, 2007, 12:22:32 AM »

Quote

This bike is a 1250 with the old motor in it

I'm sure you meant to say "NEW" motor.....right, Al ??

Well, gents, Honest Al is correct in that the 2.5G and 3 G Bandits do NOT have a normal-style petcock. Remember, this is a totally redesigned tank (amongst other things on these bikes) and Suzuki has decided that since the clocks have a fuel gauge built into them on these later bikes that, theoretically speaking, a switchable petcock shouldn't be required....provided you're attentive enough to look at the fuel gauge once every 50 miles or so.
There is STILL a vacuum operated shutoff valve in the bottom of the tank, however,.....
so there's NO worries about gas getting all over the place when removing the tank, since this valve automatically shuts off the gas when the engine is stopped.

REMEMBER: NO/NO smoking, no open flames or sparks or welding/grinding close by when performing any operation to do with gasoline. Ignition key MUST be OFF, also.

The removal process goes like this (it makes the tank easier to handle if it's nearly empty when you remove it):
1) Remove the seat
2) Remove the 2 bolts holding the back mounting tab of the tank
3) Lift the tank about 3 or 4 inches and pull it gently backwards about 3 inches to disengage the front mounting tab from its slot
4) Either block the rear of the tank up with a suitable stable support or, preferably, have an assistant hold the tank steady while YOU do the next steps
5) Disconnect the electrical connector from the fuel level sender in the tank
6) Disconnect the vacuum line from the fuel shutoff valve
7) Disconnect the main fuel line from the fuel shutoff valve
8) Lift the tank carefully from the bike and set it aside where it won't get dropped or kicked or otherwise damaged.

The reinstallation process is just the reverse of the above procedure.
Al, if you have the least doubts about your ability to handle this operation correctly/safely, I strongly recommend that you have your local dealer perform this work for you.
Safety First !!!!

Honest-Al · « **Reply #6 on:** September 24, 2007, 12:27:34 AM »

Thanks for the info. I already found what you were talking about and removed the tank a few days ago.
No, I don't mean the new engine. This is the one they call the "Final Edition". Everything on the bike is the same as the 1250 except it has the 1200 air cooled motor. I didn't want to get a "new" model anything because it seems like they always have some kind of problem with something on new models. I guess I was wrong again because the motor seems to be bullet proof. Damn!!!!

H2RICK · « **Reply #7 on:** September 27, 2007, 11:58:19 AM »

Quote

Everything on the bike is the same as the 1250 except it has the 1200 air cooled motor.

What you have there is a 2006 B12S which is commonly referred to as the 2.5 Generation (or version) which is the same bike I have. Great bikes and I bought mine for the same reasons you did: air/oil cooled with carburators but with the newer swoopier body work and FARRRR better headlight.
What's not to like.....right???

Does this look familiar???:

Honest-Al · « **Reply #8 on:** September 28, 2007, 12:32:04 AM »

Yup! That's the puppy alright. My IS the same except I don't have the clear turnsignals.
Mine is black with gold rims but I sure like your color also!!
You ain't kidding about the headlight!! I can see the next town with this headlight and the amber running lights that I installed!!
Thanks for the help. Now I know what the hell I got!!

Blade · « **Reply #9 on:** October 06, 2007, 12:52:03 AM »

To my understanding the 1250 is fuel injected. FI bikes do not have petcocks, the fuel pump is in the gas tank. All you need to do it remove the fuel line. Isually there is a lock on the fuel line so it does not come off. Suzuki usually use a lift type lock simular to the electrical kind.

pmackie · « **Reply #10 on:** October 06, 2007, 01:26:44 AM »

Hey Blade

The 06 - 1200 (2.5 gen that the US didn't get) is the Air/Oil Cooled SACS carburated engine in the new style tank and bodywork, so it looks like the new 1250.

Given it is carburated, I had assumed that there must be a petcock, but as H2Rick says, Nope, only a vacuum shut off valve in the tank. I assume the 1250 must exchange the vacuum valve for a fuel pump?

HWal · « **Reply #11 on:** October 06, 2007, 11:21:40 AM »

A few words from experience with a bike I owned earlier which had no PRI position on the petcock, like my 2004 B12 has. If the carbs are not primed with fresh gas before first startup in the spring (in Norway we have long winters), one may have to crank a lot on the starter motor.

What I did was to apply vacuum to the petcock via the hose to open it and have the carbs filled with fresh gas before pushing the starter button. The engine then started promptly.

This issue may perhaps apply to the 06 Bandit as well.

Helge.