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#Post#: 418--------------------------------------------------
Complete Tank Bolt Replacement Kit
By: Rusty Shovel Date: February 24, 2014, 7:25 am
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Thanks to Dogfarm for discovering this money saver over at
ADVrider (
HTML http://advrider.com/forums/showthread.php?t=954935)<br
/>for convenience' sake, I've reposted it here.
Everything you need to fix all tank bolts issues:
HTML http://farm8.staticflickr.com/7355/12535687303_f9d0d617e5.jpg
First some common knowledge:
KTM 690 Enduro has known issue with upper tank bolts breaking.
On this great model plastic gas tank is actually a subframe,
connected to steel tube frame on four spots – two lower bolts
and two upper bolts.
HTML http://farm4.staticflickr.com/3721/12535582455_69aa73ce2f.jpg
There is a hole all the way through lower section of gas tank.
HTML https://farm6.staticflickr.com/5513/12535581385_ee424d5fc2.jpg
Lower bolts are going through metal plate bolted to a steel tube
frame, and then are bolted to the steel tube that is going all
the way through gas tank.
HTML https://ycpi-farm8.staticflickr.com/7390/12535702893_416cb97c77.jpg
As you can see, around steel tube, between the tube and gas
tank, are rubber bushings. Those bushings are made of soft
rubber and tend to deform easily. When they deform, lower mount
is getting unwanted free play.
Because of that, pressure on upper bolts increase and they
break. Upper bolts are not made of material strong enough to
bear that additional pressure. In even worse scenario, little
metal tab welded to the frame, where upper bolts are bolted to
the frame, may crack.
HTML http://farm8.staticflickr.com/7460/12535701953_3e244b8101.jpg
There are few aftermarket solutions available, but none of them
solves all issues involved. So, I made my own kit.
So, complete subframe reinforcement kit:
1. Upper parts - upper tank bolt caps and bolts.
Upper tank bolt caps are made of AISI 4140 steel, then heat
treated (for added strength), then zinc coated (rust
protection). That makes them virtually indestructible. Size of
the head is standard – 27 mm.There is M6 threaded hole for
plastic fairing.
HTML http://farm4.staticflickr.com/3713/12535698443_b87ef787d2.jpg
HTML http://farm8.staticflickr.com/7338/12535574075_aed2fc65bb.jpg
Bolts are 10.9 machine bolts, zinc coated. These are much
stronger then OEM upper tank bolts. 25mm long, so 1.5mm is in
the bolt cap, when mounted on the bike. That is very secure
connection.
HTML https://farm4.staticflickr.com/3693/12535572685_d42075ca23.jpg
HTML http://farm8.staticflickr.com/7318/12535694803_860b619e8e.jpg
2. Lower parts - lower bushings, steel sleeve, stud, nuts and
washers.
Lower bushings are made of strong plastic, much stronger then
OEM rubber lower bushings, yet gentle enough to be in close
contact with plastic tank (rubber OEM upper bushings are kept,
because completely rigid tank-frame connection wont be a good
thing). Slightly different size, so they fit better (really
minor differences in size).
HTML http://farm8.staticflickr.com/7443/12536068344_f2a83cdbe7.jpg
Sleeve is made of AISI 304 stainless steel, without internal
thread.
HTML http://farm8.staticflickr.com/7421/12536067154_90bb5924ed.jpg
Long stud is made of AISI 4140 steel, heat treated (for added
strength), then zinc coated (rust protection). Stronger then
10.9 bolts – very strong. Close fit through sleeve. Part of stud
witch goes through steel plate welded to the frame is not
threaded so fit is closer - that contributes to strength of this
joint.
HTML http://farm3.staticflickr.com/2805/12535570245_674a50ff46.jpg
HTML https://farm4.staticflickr.com/3738/12535568755_d14151e456.jpg
HTML http://farm4.staticflickr.com/3830/12535689703_8f5b1d9263.jpg
Washers are standard stainless steel washers and nuts are
standard stainless steel safety nuts.
HTML http://farm8.staticflickr.com/7294/12536051884_413931494f.jpg
This is everything you need to fix all issues regarding tank
bolts. Everything can be installed using standard tools, without
advanced technical knowledge, in less then an hour. Including
break for beer or coffee.
Practical, strong design and quality of materials were
priorities, not aesthetics. This could look nicer and fancy
(different coating), but price would go considerably up. This is
not something I do for living, so I don’t plan to make money out
of this, but I do tend to cover all expenses. Here are
calculated prices:
Set shipped to USA - 60 Euros (82 USD).
Set shipped to Europe - 55 Euros.
I am using Serbian post office services, with tracking number.
They are good, never lost a package. Yet. Usually it takes 14
days for USA and 7 days for Europe.
PayPal payments.
If interested, PM me with your name and address and I will
inform you of PayPal details.
Based on latest knowledge: my set is designed for 2008-2013
models. On 2014 model silencer mounts on lower bolt, so I need
to make longer stud. Hopefully, I will do that next week, and I
will post it here. Meanwhile, please keep in mind that this set
is for pre-204 models. Many thanks to Sieg for heads up!
#Post#: 420--------------------------------------------------
Re: Complete Tank Bolt Replacement Kit
By: Perun Date: February 24, 2014, 8:33 am
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Hello everyone, this is my first post here. If you need some
additional info regarding these items, please feel free to ask.
#Post#: 421--------------------------------------------------
Re: Complete Tank Bolt Replacement Kit
By: Rusty Shovel Date: February 24, 2014, 8:59 am
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Hey Nikola, glad you joined us!
I was wondering how things were coming with the 2014 tank
replacement bolts? I understand that part of the exhaust shares
the lower tank bolt on the 2014 model. Also, do aftermarket
pipes utilize the tanks bolts on the 2014?
I'm about to install a Wings pipe, so I'm curious.
Rusty
#Post#: 423--------------------------------------------------
Re: Complete Tank Bolt Replacement Kit
By: truck11 Date: February 24, 2014, 3:32 pm
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Interested to see how the 2014 differs from prior years. Anyone
have any other thoughts on this preemptive fix?
#Post#: 424--------------------------------------------------
Re: Complete Tank Bolt Replacement Kit
By: Perun Date: February 24, 2014, 3:53 pm
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According to my information, tank mounting hardware is same for
all 2008-2013 bikes, including 2013.
KTM did make a change on 2014 model, but they didn't improved
anything, they just added lower exhaust bracket on lower "tank
bolt", so longer bolt/rod is needed. All other tank mounting
parts are same on 2014 and pre-2014 models. I made new threaded
rod (longer one) for 2014 model, but still need to see how it
fits on the bike, so I am not selling it yet. I will send new
threaded rod to a friend in USA, who has brand new bike, and he
will see if it fits.
I expect to have set for 2014 model (actually its the same set,
just with longer threaded rod) ready in ten days or so...
I read somewhere that Wings is making additional bracket for
2014. model, but cant remember where... ???
#Post#: 456--------------------------------------------------
Re: Complete Tank Bolt Replacement Kit
By: Tmblwd Date: February 26, 2014, 6:10 pm
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Hey perun just ordered my bolts, due to ship tomorrow, I will
post something about putting it together.
BTW Gorazd, at wings is great to work with he sent me his new DB
buster and I like the sound. If you have any questions about the
fit of the 2014 pipe his email is mf@siol.net
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