Gas tanks expanded, won't fit back on

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by weed099, Feb 26, 2011.

  1. weed099

    weed099 Been here awhile

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    I took my 2005 950 Adventure apart to replace the waterpump, which it turns out it was probably fine. But now I am putting it back together and the gas tanks don't fit. I noticed something wasn't right because the fuel tank was rubbing the side panel, which I didn't think it was that close o a fit when I took them off. Now trying to get the crashbars on, I can't even get the tanks bolted up. Nothing lines up right to get the bolts in, even without the crashbars. I'm stuck, what now?
    #1
  2. cpmodem

    cpmodem Orange Caveman

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    They do that when you take them off when they're full or near full. Just get the top hole centered over the threads and stick the bolt in 2-3 turns. Then do the rear bolt the same. Now wiggle and push all of the loose ends together at the front hole. The nut will slide around in the over large opening in the mount. Tighten all the bolts starting with the rear, then top, and finally the front. Tighten the crash bar's other mounts last. Next time empty the tanks first. Its easier to get back together that way.
    #2
  3. scapegoat

    scapegoat Pushin forward back

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    Ive had the same issue every time Ive torn my down. Studding the front crash bar mount helps a bit also. I start the top tank bolt just to keep in place then attack the front lower which always seems the worst. I generally have to push up pretty hard on the tank to line up the hole, then the top and the others as needed. Rule #1, never snug up anything until their all at least started a few threads.
    #3
  4. switchback

    switchback Eatin' Dirt Since 1982

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    Ethanol is causing this same problem with plastic based tanks on many different models and brands. Thank Congress and the corn subsidies for this one.
    #4
  5. weed099

    weed099 Been here awhile

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    I started with the top, then the rear, but the bottom won't line up. I can't even get the crashbars to mount to the frame. The tank seems like it expanded too much. Complaining of gas fumes, my dad set them outside in the sun today. Any suggestions to get them shrink back.
    #5
  6. cpmodem

    cpmodem Orange Caveman

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    Try emptying them. Get them out of the sun. Leave the top bolt loose so the tank can raise up that inch or so.
    #6
  7. weed099

    weed099 Been here awhile

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    They are almost empty. Not much gas in them. They are now in the basement, hopefully cool down and shrink some.
    #7
  8. Doug Matson

    Doug Matson Long timer

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    When this happen to me a few years ago I lined up the top bolt and the back, kept them loose then put a floor jack under the bottom of the tank and jently jacked it up until the bolt was started. I think the next time I take them off i am going to make up a jig to bolt them to so this won't happen again.
    #8
  9. crazybrit

    crazybrit Long timer

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    Yup. Always empty the tanks before leaving them off. Chuck the gas in your car. Refill when done. Easier to move the tanks around. Also useful if you were a bonehead and let your KTM dealer do the top crossover TSB :cry
    #9
  10. Scottyman

    Scottyman Blue & Orange

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    I did the same maneuver with the floor jack, works like a charm!
    #10
  11. MortimerSickle

    MortimerSickle Semi-Adventurer

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    #11
  12. viola-tor

    viola-tor Needs to ride!

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    Mine warped too, before I learned about the problem of having them off when full. DOH!

    It's awkward, but I start with the BOTTOM bolt first, crash bars and all. I balance the whole thing on my knees and wriggle and wrestle until I get a couple turns threaded in, then go on to the top and rear bolts which snug up pretty easy, a little at a time on all three bolts.

    You can do it! Patience... It's just a little extra "bonding time" with your bike, next time it'll be easier.
    #12
  13. M.Mars

    M.Mars híppos leukós

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    AHHHHH son of a biiiiitch !! I had my tanks off for about 3 months now and they are 3/4 full. IS this whats awaiting me ?!?!

    :baldy :kboom
    #13
  14. crazybrit

    crazybrit Long timer

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    Different question. What were you thinking that gas was going to be good for after sitting in the tank for 3,4,6 months? I'd add it to your car's mostly full tank now and put fresh into the ktm when you're ready to reinstall.
    #14
  15. sstewart

    sstewart Long timer

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    Make sure to cuss,kick and throw shit. It helps from time to time.
    #15
  16. DrKayak

    DrKayak Retro Rider

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    The bottom front bolt is clip type the hole can be drilled out allowing that clip bolt to slide down and out. I did this simple mod the second time I had my tanks off. Last 2 times they have gone on super easy.

    This has been posted in other threads. Several have had sucess with the extra inch or so you can gain.
    #16
  17. mamacone

    mamacone Been here awhile

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    I called my riding buddy and said I needed his expertise. He came over and I sat and watched him wrestle it. Actually, had to do the opposite and let it sit in the sun awhile.
    #17
  18. M.Mars

    M.Mars híppos leukós

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    yeah the idea was to drain the tanks but i never got around to it. Just put them in the back with all the other panels and focused my attention to the engine work.
    #18
  19. weed099

    weed099 Been here awhile

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    After sitting over night they still aren't fitting. I took the back bolt out, left the top in, and inserted the front bolt. With those two in, I attempted to bolt in the rear. The tank was hitting the frame below where the rear bolt goes in. I'm trying MortimerSickle's trick with PVC pipe and strapping the rear of the tanks to get them to curve.

    [​IMG]
    #19
  20. Roughidle

    Roughidle Super Star Destroyer....

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    On a slightly different note.


    My tanks still fit ok, but the are noticeably swollen in every dimension. For example there used to be almost an inch of space between the rear crash-bar clamp, and the bottom of the tank, now they are all but touching.

    I phoned a somewhat local dealer who is familiar with Lc8's, he said that he has seen this before, and that he has never been turned down by KTM for warranty replacement of the tanks. Apparantly it falls under the "emissions warranty".
    #20