Gen2 Bodywork, fuel tank cover

[herveyw]

The body work has been off my bike for a few months while I have been fixing things after a deer encounter.

Last weekend I had made enough progress to refit the bodywork but ran into an issue: the final tank cover piece that goes over the filler cap does not fit properly, it will not sit flush over the end of the fuel tank nearest the seat.

The two side panels seem fine, they fit in place around the tank, and the bolt holes into the tank mount under the seat all line up. However when I place the tank cover part on, it simply will not go down over the end of the tank and wants to pull the side panels up such that the bolt holes no longer line up. There isn’t enough “give” for me to want to force it.

I checked the fuel tank mounting and it is as far forward as it can be but cover still won’t sit flush. I am starting to wonder whether the fuel tank has deformed.

Has anyone run into this problem?

[smithy]

Originally Posted by herveyw

The body work has been off my bike for a few months while I have been fixing things after a deer encounter.

Last weekend I had made enough progress to refit the bodywork but ran into an issue: the final tank cover piece that goes over the filler cap does not fit properly, it will not sit flush over the end of the fuel tank nearest the seat.

The two side panels seem fine, they fit in place around the tank, and the bolt holes into the tank mount under the seat all line up. However when I place the tank cover part on, it simply will not go down over the end of the tank and wants to pull the side panels up such that the bolt holes no longer line up. There isn’t enough “give” for me to want to force it.

I checked the fuel tank mounting and it is as far forward as it can be but cover still won’t sit flush. I am starting to wonder whether the fuel tank has deformed.

Has anyone run into this problem?

Are you able to put up a pic or three..?? Somebody who owns a Gen-2 might spot something you may have missed.

Smithy.

[herveyw]

Images as requested:

The first photo shows the black tank panel aligned with the bolt holes in the red panel, the second image shows that the bolt hole for the red panel does not line up with the slot in the fuel tank mount. If I bolt the tank panel to the red panel, I cannot get the hole in the red panel to align.




The first photo here shows the black tank panel position when the hole in the red panel is aligned with the slot in the tank mount. You can see the gap from the black panel to the red panel at both the bolt holes where they connect, and the gap nearer the top of the tank where the two panels should be flush - the black part has popped out of the clips.




Overall, it is like the black piece no longer fits on the tank, I have tried moving the tank into multiple positions with no luck.

[af1-windy]

Are the tanks plastic (or some sort of composite) I recall the tanks on the early Tuonos expanding slightly, caused by the ethanol in fuel. It used to be a right pain in the rear, re fitting the tank..

Just a thought 

  windy

[Col_C]

Originally Posted by af1-windy

Are the tanks plastic (or some sort of composite) I recall the tanks on the early Tuonos expanding slightly, caused by the ethanol in fuel. It used to be a right pain in the rear, re fitting the tank..

Just a thought 



  windy

Yes Triumph had similar issues in the 2000's but I would think all manufacturers are using ethanol tolerant materials 20 years on.
Perhaps the tank got shunted forward in the frame during your deer encounter and needs to sit further back?
Getting good panel fit is sometimes counter intuitive.

[af1-windy]

Originally Posted by Col_C

20 years on.

Damn, where did that go.. 

[Col_C]

Originally Posted by af1-windy

Damn, where did that go.. 

[herveyw]

Originally Posted by Col_C

Yes Triumph had similar issues in the 2000's but I would think all manufacturers are using ethanol tolerant materials 20 years on.
Perhaps the tank got shunted forward in the frame during your deer encounter and needs to sit further back?
Getting good panel fit is sometimes counter intuitive.

Ducati had some problems too, around 10 years ago if I recall correctly. I have not found anything on the web that suggests BMW ever had any problems.

I’ve spent quite a few hours fiddling with the panels and tank position to no avail, it has become the proverbial head scratcher. Unlike other parts, there is no simple way to rule out a problem with the tank itself; it’s not obviously out of shape and the panels were on the bike until I took them off once I was back on my feet. Just the dangling question of whether a few months sitting caused it.

I’ll have another crack at again this weekend, beyond that the options seem to be either drain it completely and let it dry over the winter or get another one. It’s frustrating because I am essentially done with the myriad repairs.

[capt cf]

Originally Posted by herveyw

Ducati had some problems too, around 10 years ago if I recall correctly. I have not found anything on the web that suggests BMW ever had any problems.

I’ve spent quite a few hours fiddling with the panels and tank position to no avail, it has become the proverbial head scratcher. Unlike other parts, there is no simple way to rule out a problem with the tank itself; it’s not obviously out of shape and the panels were on the bike until I took them off once I was back on my feet. Just the dangling question of whether a few months sitting caused it.

I’ll have another crack at again this weekend, beyond that the options seem to be either drain it completely and let it dry over the winter or get another one. It’s frustrating because I am essentially done with the myriad repairs.

Yup, your memory is correct.  I had one of the affected Ducatis (2010 1098 SF).  The fuel tank swelled and impinged on the ignition area, etc. and had to be swapped out.  If I recall, they were measuring the amount of tank swell and if it met their definition of "problem" they were replacing with exactly the same tank/materials so it was bound to happen again down the road.

[Col_C]

Originally Posted by capt cf

Yup, your memory is correct.  I had one of the affected Ducatis (2010 1098 SF).  The fuel tank swelled and impinged on the ignition area, etc. and had to be swapped out.  If I recall, they were measuring the amount of tank swell and if it met their definition of "problem" they were replacing with exactly the same tank/materials so it was bound to happen again down the road.

Sounds familiar Ducati philosophy, I had a Multistrada (10yrs ago) fitted with several failed fuel gauge senders and condensation in instrument panel, same components = same result, got rid at the end of the warranty period.
One hopes they've learnt some lessons since then?