Expanded tanks

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by lenny6753, Dec 22, 2012.

  1. Trailie

    Trailie Can still fog a mirror

    Joined:
    May 27, 2006
    Oddometer:
    27
    Location:
    Virginia
    I have had the problems discussed above with expanding tanks with the same results to replace them. As to KTM replacing tanks, mine are cracking on the outside through the paint, though not leaking yet, and they say that my 2005 Adv is too old..Thanks KTM, for standing behing your product.
    #41
  2. two trackin fool

    two trackin fool Long timer

    Joined:
    Nov 6, 2010
    Oddometer:
    1,328
    Location:
    Mobile with any Luck
    :lurk Wow just getting ready to tear mine down for winter maintance . Glad I read this first . I will probley empty mine and take them in the house. As they will be off for some time ..........
    #42
  3. lenny6753

    lenny6753 Adventurer

    Joined:
    Apr 9, 2010
    Oddometer:
    88
    I was finally able to fit the tanks back on the bike. I used a dremel tool and extended the hole in the top plate down about a 1/2 inch to 3/4 inch. I still had to keep the top bolt very loose and fitted the back bolt after I had the top and bottom one in place. Someone mentioned the petcocks my strike the top plate. I am keeping an eye on this and it appears the petcocks do not come in contact with the top plate even though the hole is extended. My only concern with doing this so far is that the rubber fuel hose that crosses between the two tanks to the petcocks may have a little more force on them near the petcocks but not much.

    I will see how this works for the time being. I may purchase another top plate and replace this one later on down the road when the tanks get back to their appropriate size. Thanks again for everyone's suggestions and help. If I had to do it again I would not leave the tanks off for any extended time period.
    #43
  4. ciedema

    ciedema мотоциклист

    Joined:
    Oct 14, 2007
    Oddometer:
    1,971
    Location:
    On the road! Finally!
    From reading this thread - it sounds like it is best to leave the tanks full as they wont absorb water and to stand them up.

    I have mine off for extended periods (2 months) and left them standing up, about half full, closed in a very humid environment (Brisbane Qld) without this problem.
    #44
  5. HeatXfer

    HeatXfer Bad knees

    Joined:
    Feb 18, 2008
    Oddometer:
    764
    Location:
    S.F. Bay Area
    The stock tanks did this on my '07 990. With the top and rear tank bolts in place, I found the bottom (front) tank bolt holes were 3/8" below & forward of the mounting points on the cast aluminum piece above the battery box (the "top" of the stock skid plate).

    I used a floor jack (to lift up) and a 2x4 (to lever the tank back) until the holes lined-up. I could see the tank bow out a bit as I set the bolt.

    I've got the process down now, although I wouldn't want to try it on the trail.
    #45
  6. Hike&ride

    Hike&ride Exploration Born

    Joined:
    Feb 19, 2012
    Oddometer:
    11
    Location:
    North Carolina
    Just a thought..if its humidity, get a dehumidifier and crank it up. might help..especially in a small room.

    As far as me. I just had my tanks off for over a month, Did lots of maintenance, plus some farkles. I live in North Carolina near lots of swamps, very humid wet air. My tanks where about 3/4 full. I didn't vent them. I actually capped every vent opening and zip tied every hose. no air was going to get in. When I mounted them back up, not one single problem. My method my not work for others but it works for me so im gonna stick to it! Good luck and sorry your having to deal with it!
    #46
  7. ACP

    ACP Adventurer

    Joined:
    Aug 15, 2008
    Oddometer:
    80
    Location:
    New Forest NP, Hampshire
    I just read this thread last week and I was pretty apprehensive about putting my tanks back after they've been stood in my cold, cold damp garage for some 8 weeks.

    They stood on end, caps closed with about a litre of fuel in each. Followed the advice here and left the battery cover plate loose and they went back on like a dream. No problemo...

    AFAIK, we don't have any ethanol in our fuel here in GB though I did read about it being introduced in the future. I look forward to that like a hole in the head!!!

    Seems a very random whether they expand or not. Ethanol, no ethanol, humid, hot, cold, vented, sealed?! Who actually knows why?
    #47
  8. jfh

    jfh Adventurer

    Joined:
    Nov 18, 2008
    Oddometer:
    45
    Location:
    cornwall uk
    I'm not sure you are right about uk fuel. See

    http://fbhvc.co.uk/bio-fuels/

    I beleive my 950 tanks were effected by the ethanol in the fuel and eventually my dealer was decent enough to supply me with one replacement tank for the right which was most distorted.
    #48
  9. Trailie

    Trailie Can still fog a mirror

    Joined:
    May 27, 2006
    Oddometer:
    27
    Location:
    Virginia
    My right tank bottom mount was about 1/4" off, not too hard to get right, but the left tank was nearly 3/8. Someone on this thread suggested removing the back screw, and that helped.
    I have decided to line the tank with the Caswell product. I sluiced the tank out with lacquer thinner, washed it out with hot soapy water and rinsed it. Got the tanks back on and hooked my air compressor to the bottom petcock. After flowing air through the tank at very low pressure for 24 hours on each side, all bolts will go in without any force. I am hoping that, after I put the Caswell sealer in both tanks that they won't absorb water any more. Then I can try to make the cracks in the outer coat less obvious. Any ideas about spot painting? I not going to get too worked up about an 8 year old motorcycle, even though I love riding it.
    #49