FRONT FUEL TANK BOLT !

cjc

2009-03-31 19:05:00 UTC

The fuel tank bolt has gone from the allen bolt to a 2.5"(63.5mm) stud, one end was deeper than the other with threads,

one end was at 14mm the other was 17mm here is a pic of the chosen stud with green (lightweight) locktight. the blank or center part is raised, (thicker).

Here it is with the stud tool on installation..

this is the chosen shouldered nut, this part is from a auto belt adjuster/idler/tensioner, not sure what type of car, it was Japanese.

Here it is installed, not pretty as the allen but OH!! how easy it is to install now.. a no brainer, this is especially noice for one (1) small.......... joe..

another pic for you. all comments and suggestions/question are welcome. Peace is what I give you..

as you all can see.... I chipped the coating on the tank tryin to get this f@cken allen back in, now I have gone before you to master this hazardous place.

Just had to decide to open the can of woop arse.

Motohooligan

2009-03-31 21:03:00 UTC

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bill34

2009-03-31 23:15:00 UTC

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CrotchRocketeer

2009-03-31 23:20:00 UTC

Thanks cjc, & M0T0!! I did my arse today also looky here mates all..

Zenbiker

2009-04-01 00:27:00 UTC

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overthetop.ca

2009-04-01 00:31:00 UTC

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KTemmer

2009-04-01 03:03:00 UTC

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Zenbiker

2009-04-01 17:53:00 UTC

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KTemmer

2009-04-01 17:59:00 UTC

Thanks Rob, I try to keep the party goin ya know, I mean come on... you can go to endless places to read endless topics but to stir the imagination we must.

Jeezus, talk about funny, I will tell you all some secretive stuff too, I have been making my friends laugh since I was a little kid so this is all natural to me.

but my wife..... god she is funny! i would make my friends laugh so hard when we were young to the point they would piss thare pants,

and my wife puts me to shame...

how's this for funny, my tag braket melted but is still working, I will figure something else out, hell in the smokies they do not run tags blinkers or lights..

~~~~~~~~ blinkers are incorporated into the bottom bar^^^^^

Zenbiker

2009-04-02 21:39:00 UTC

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Zenbiker

2009-04-02 21:48:00 UTC

well you!! I have it fixed now... what do ya think of these apples..

the turn sigs were in the bracket now they are ontop of the euro lamp.. now I have a tag lamp, a custom aluminium bracket for the tag... all heat insulated too..

Legal smeagal..

Chris

2009-04-10 19:43:00 UTC

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optimus prime

2009-04-11 00:02:00 UTC

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collyer

2009-04-11 00:40:00 UTC

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optimus prime

2009-04-11 03:21:00 UTC

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collyer

2009-04-13 11:49:00 UTC

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Zenbiker

2009-04-13 14:36:00 UTC

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Zenbiker

2009-04-13 16:24:00 UTC

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Gregz

2009-04-13 16:28:00 UTC

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Colonel_Klinck

2009-04-26 22:28:00 UTC

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the-bunker

2009-05-02 23:23:00 UTC

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MonkeyDuke

2009-05-03 09:59:00 UTC

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KTM666

2009-05-03 22:12:00 UTC

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nampus

2011-09-08 01:55:00 UTC

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jambox

2011-09-08 05:05:00 UTC

This is my post from a tread about the same thing.............

There is a little trick, take out both rubbers and cut back on one side on both just the tube part...install with cut out to the back (closest to the seat

Here you are...er ...this was never mean't to be seen ...leave alone close up...so not exactly Precision cut

No ill effects and works every time.....I had forgotten what a pain it was until I read this

DribbleDuke

2013-05-06 02:46:00 UTC

This is annoying. I popped the tank off for the first time. Tank was almost empty and right after I undid the bolt, I could see that tank expanded/de-stressed. It wasn't going to line up w/ the bolt hole.

I tried this * wonderbar *

and it works. Simply put this against the steering stem and press the tank down on the frame. You can manipulate as needed.
You have to be extra careful or you'll peel a couple layers of plastic like I did.

Good luck!!

dougle

2013-05-06 12:48:00 UTC

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enigma990

2013-05-06 16:51:00 UTC

Putting in the front bolt first, and then the 2 rear bolts also works quite well.

KTM666

2013-05-08 08:01:00 UTC

Nampus, I’m with you on this one. Slacken off the hinge bots at the rear of the tank until they are ready to fall out, front bolt slips in a treat. Keeping the rear hinge bolts just in place means you don’t then have to fight with the rear of the tank pushing against the gas strut.

Stupid Luke

2013-05-08 16:54:00 UTC

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Willh

2014-05-05 10:14:00 UTC

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DribbleDuke

2014-05-06 03:23:00 UTC

With all due respect- the problem with the tank bolt is caused from the "iron fist" strut, it is too powerful for the job and this is enhanced by the "floating rear pivot bushings.... the proof is in the pudding, if you raise the front of the tank full of gas or empty with out the strut attached, then waste no time for the floating bushings to recenter themselves, you shall indeed see the bolt hole will be perfectly aligned. Case then point.

Willh

2014-05-06 04:44:00 UTC

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Jim H

2014-05-06 09:54:00 UTC

Great to see you posting Joe.

My strut was removed when new and the problem manifested over time.

Jim H

2014-05-06 14:41:00 UTC

Humm..... manifests over time? Could it be possible the pressure relief valve is not relieving the pressure? I have to say I have not witnessed this occurrence of pressure in my own pumpkins tank, time can be an unfriendly foe indeed if not dealt with properly. As many of you may know?... I have had my tank up and down too many times to count, when she was less than a year old I had caused some minor damage trying to get the friggin front tank bolt back in, this was precisely why I devised the stud+shouldered nut methodology technique to address the encumbrance, since that time I have not had another instance with the PITA.

Pertaining to your concerns DD, you can always slip me a PM, I would not mind a bit.

Thank you folks for the warm welcome.

bazz21

2014-05-06 15:05:00 UTC

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MADDOG53

2014-05-06 17:41:00 UTC

Jim H....what happened with the court case last week?

Willh

2014-05-06 17:44:00 UTC

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scamb66

2014-05-07 08:53:00 UTC

i do feel for all u guys with tank swelling this is the 3rd bike ive had with a plastic tank and never had a problemo ill tap some wood now cheers bazz

Jim H

2014-05-07 10:46:00 UTC

Fast gas is the only "real" answer to tank swelling,,,and it "is" the best thing to store in the bike for any period of time,,,,,,

scamb66

2014-05-08 03:39:00 UTC

Maybe do some posting to KTM, not that would do any good but a recall may be in order-

I will not argue the fact but in the scientific realm no one here has given any exact measurements, for example (hard to do I know), #1: Remove the tank. #2: Measure the tank hold-down fastener hole distances. #3: Measure the frame bolt hole distance, on and on..

joe was a machinist (tool and die grinder, production lathe) prior to his life long career as a heavy line auto technician, this is a world i do understand as far as nuts and bolts are concerned, STEEL nuts and bolts that is, when you mix a petrol based fuel cell with fuel, hard to say what to expect, but to conclude, as a very well thought out MC engineering and design company it is impossible to perfect everything, I find it hard to believe KTM would let this slip by them.

Best question may be why do some have shrinkage/expansion issues and some do not?

ktmguy

2014-05-08 09:46:00 UTC

While you were gone Joe, a several problems with the tanks arose. Some tanks swell, some got mumps or acne, others may have shed their paint. Moto hooligan made new tank brackets to make replacing tank easier. It seems that not all tanks are made equally. There are members who have been through several tanks. Others who have had no problems. The fix so far has been sealing the tank. I don't see this as being a good long term solution with today's fuels. Could be potential problem down the line with sealing material causing problems with the fuel injection/filters if/when it deteriorates.
Ducati used the same manufacturer and material and it is well documented the problems had by their owners. They and others are returning to metal for the tanks.

scamb66

2014-05-08 22:29:00 UTC

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Jim H

2014-05-08 22:51:00 UTC

Ethyl alcohol fuels, both petroleum & diesel. No secret anymore. More problems arising from this corn syrup shit.

Aussies seem to be lucky ones. Enjoy while it lasts.

You guys don't have year round humidity (no offence) you wouldn't know. Nice dry climate etc. It affects, trust me, stupid fooking plastic tanks.

bazz21

2014-05-09 01:25:00 UTC

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Jim H

2014-05-09 03:18:00 UTC

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