Fookin Tank

I had to lift the petrol tank yesterday so I could get to top up my coolant. I removed the bolt near the headstock and the panels attached to the tank and got the wife to hold it up a few inches so I could add coolant. Job done, I lower the tank down to re insert the bolt I had merely removed, only to find the bolt did not line back up with the threaded hole it had just come out of . I then gripped the tank with my hands and started to wiggle the tank back, but it was not having any of it. I then removed the 2 bolts at the back of the tank and managed to get the tank back the 4mm it needed to realign the bolt. I got the bolt started and then had to somehow get the other 2 bolts in at the back of the tank.Using a screwdriver , I stuck it right through one of the holes for the rear bolts and used as little force to realign it so the other side could get started and just about managed it. The other side then went home, but not without a struggle, and I then tightened all 3 bolts. What should have been simple turned nasty and the tolerances for the holes to line up are frankly shite and I dont want to lift that tank again now

what year is your bike?

Its an infuriating design flaw which gets much worse when the bike / tank gets hot.
Ive even had to unbolt half the subframe before now in order to access the injectors while the motor is hot.
I've seen adverts for moveable rear tank mounts but don't know if this fixes the problem or if anyone has used them.
Anyone?

I think everyone who has ever lifted the tank on a SD has suffered this problem. I found my front SAS plate easier than getting the fooking tank bolt back in!

My only tip would be to make sure the fuel tank is as empty as possible before lifting it, this way it moves less under its own weight when propped up.

I have to swap air filters on Thursday and I'm dreading it for this very reason!

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)

Its A mk1 2005 (2007 plate)

No problem I will do tomorrow.....(no power in the garage)

The coolant I bought had a long snout on the end which pulls out so no need to lift the tank.

I run a loading strap around the front of the tank & back through the rear foot rests, one continous loop and slowly tighten the ratchet until the bolt hole lines up.

Worked OK last time. Tank shrouds off etc.

mine can't have been that far off... I just used the guns

Thanks for a top tip with those rubbers fella - I will try that. The bloody thing drives me mad!

Never had an issue with mine and its gets quite warm here (45C) so dont think temp is an issue. What we dont have here is ethanol in the fuel (yet) so dont know if that makes any difference. Any other Aussies had any issues with this?

Tell me about it. The third tank on my Ducati is in need of replacing already, and the bike is only five years old. Been trying to get the local KTM dealer to start the warranty process on my SD as well. Guys don't really seem interested in it, so I guess I'll just have to move in to their shop until they do...