Big thumbs up to the KTM USA peeps. I called this morning re my swollen tank, and they're already onto my local KTM dealer to get me a new one. No problems. Fantastic and looking forward to my new, fitting tank.

Question: should I get the dealer to seal the tank or should I just order the stuff myself? Anyone know what I should get if so?

Caswell seems popular for coating inside of tanks.

Why would one "seal" a new tank?

Does anyone know if Caswell's epoxy adheres to polyamides well?

So what's the name of that KTM dealer .

my tank is a bit oversize with a couple small pimples , certainly wouldn't mind a new tank

shiat i see y ou're on the other side of the continent from me

Problem is not poly tanks,,,problem is E10 ETHANOL fuel getting shoved down our throats

KTM should supply us all with carbon fibre tanks made with vinyl-ester. No sparks, no swelling, no leaching/dissolving of the resin, no rust. Works for me

Come to think about it, a nice aluminium tank would make me happier.

From what I've read, the tank sealants used on fibreglass tanks tend to fail from the ethanol over time, causing more trouble...

I have had zero issues since getting my replacement tank (warranty) back in 2011. I run ethanol free fuel when I can find it. Never considered lining the tank.

KTM replaced my tank over a year ago due to the mumps/distortion problem that seems to trouble many of the polyamide tanks sold to the US market. I had my local dealer send the replacement tank out to Hattar Motorsports (a west coast Ducati dealer) and had them coat the tank before it ever had a drop of fuel put in it. So far (1 year and 3 months) so good, there is absolutely no sign of mumps or distortion of the tank that I can detect whatsoever. Yes, there's a chance the lining could go bad but I'm certain there's an even greater chance that an untreated polyamide tank will eventually suffer the same fate as my original tank. If you go to the Ducati forums you'll find guys that are on their 5th replacement tank because Ethanol destroys the tanks almost as fast as Ducati can replace them.

I agree with those that would like to see the new SD come with a polyethylene fuel cell with pretty painted cosmetic side panels. I can assure you I won't buy any new bike that uses a polyamide tank again. As horrible as it is to say if I were buying a new bike today it would be a Triumph Speed Triple (perish the thought!) for the simple reason that it has a metal tank.

Rumors say that KTM changed the the manufacturer of the tank, its now made by Elcamet in Germany. No more Swelling.

Not a rumor...my new tank was made by Elkamet. Old by Acerbis.

Has the Elkamet tank been proven to be a fix? Made of the same PA6 nylon as old tank. Finish is slightly glossier and tank seems a bit heavier. Manuf date 1/12

After my '06 tank replacement my dealer told me that KTM instructed that I should use fuel stabilizer at all times. After talking with the Ducati dealer (they have the same problems with certain models) I settled on adding fuel stabilizer AFTER the ride when the bike is going to sit for a week, rather than trying to carry a bottle to add at each fuel stop. Don't know if this is the solution. DUC dealer did have one other interesting comment; his rep tells him Ducati has shelves of returned tanks that have been sitting open and empty and have returned to their original shape.