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Old 07-28-2013, 09:20 AM   #1
ramjet OP
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Re: KTM 690 Lower Tank Bolt Replacement

I got the Rally Raid upper and lower tank bolt replacements. Upper no problem. But the lower was difficult to get in because the bolt shoulder that fits between the frame mounting flanges seemed to be about 1/16"+ longer. Such is not the case however. The stock bolt was actually .001 longer than the Rally Raid. In other words, the frame mount flanges compress that lower tank bolt area significantly. This makes alignment of the holes while installing the lower tank bolt a challenge. I can imagine the fun lift the tank on the trail and having to fuss getting it back together.

Anyone experience similar difficulty?
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Old 07-28-2013, 08:44 PM   #2
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Just making sure you know about edog's videos of the mod in question.

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Old 07-28-2013, 09:25 PM   #3
ramjet OP
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The instructions currently with the bolt kit don't have you disconnecting the fuel line; just raising the tank a couple inches to get the OEM sleeve out. When I did this, I heard a slight ping. That was the sound of the sleeve clearing the right frame mount. What Im getting at here is the distance between the frame mounts is slightly narrower than the length of the OEM sleeve. This "squeeze" makes it difficult to tank bushings realigned with the holes in the frame mounts.
Whereas in the video it looks like he dropped the tank back down and just drove the bolt through.

Maybe my bike is just weird...
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Old 07-28-2013, 09:26 PM   #4
TheMuffinMan
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I didn't have a problem with my 2012. Installation took me 15 minutes.

Do you have a picture of what you're describing?
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Old 07-28-2013, 09:32 PM   #5
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Yeah, mine went in with ease as well. I had more problems getting the OEM set up out than getting the RR set up in. Had to use a jam nut to get both bolts out of the OEM.
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Old 07-28-2013, 09:34 PM   #6
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Installed mine a couple of weeks back,

took myself and the mechanic sometime to figure out. but yeah with another person's help would help alot.
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Old 05-17-2015, 02:55 PM   #7
NorKTM
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Hello,

ramjet, I understand your problem, because it is exactly the same problem on mine.

When I took the lower mount off on mine, to change fuel filter, I had to grind off a little bit on the lower bolt sleeve, the OEM one, to get it back in.

Now I have bought the RallyRaid lower and upper mount kit, and I have the same problem, that the fit between the frame "ears" are narrower than the length of the new RR lower tank mount spacer.

So, I think I have to grind a little bit off this new RR spacer also.

For info I have an 690 SMCR 2012.
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