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corndog67 03-16-2013 05:16 PM

KTM 950 SM Gas Tank Issue.
So I put a CPRFab air filter kit on my 950 SM and rejetted while I was in there. And cannisterectomy. Getting it all buttoned back up, set the tank on there, put the fuel pump and lines on, and I can't get the screw at the back of the tank started, it's about a whole diameter of the screw off, meaning the steel/rubber bushing mount thing isn't lining up over the hole. Well, damn, I figure that maybe, something is sitting high with the new airfilter setup, so I take it back apart, the carbs appear to be sitting down on the spigots, the air filter base is seated all the way, and I don't see anything interfering with the tank.

I put the tank back on without the air filter, and it seems that it still doesn't fit.

Is there any issue (ala Ducati) with the tanks going out of shape because of the fuel? Or am I just being a bonehead and missing something that I should be doing?

Any help is appreciated.

PowerCell 03-16-2013 05:35 PM

Check the left side lower mount... make certain it is sliding into the support slot. Right side rarely causes issues...


Chuckracer 03-16-2013 05:36 PM

They stretch if off the bike for long enough. Drain it and let it sit for a couple days, or flex it and force the bitch into position. It will go if you get pissed enough. Watch the side mounts...that's where its stopping you. You got to squeeze it together.

corndog67 03-16-2013 05:41 PM

Thanks guys, will try everything. The tanks been off for about 3 weeks.

It'sNotTheBike 03-16-2013 06:51 PM


Originally Posted by corndog67 (Post 20963706)
Thanks guys, will try everything. The tanks been off for about 3 weeks.

If you can warm the tank up by placing it in a bath
of warm water for 30 minutes or so, the plastic will become more
compliant. Obviously you want to make sure gas doesn't exit the
tank and water does not enter the tank. As long as you don't submerge
the vent and keep the petcocks closed you should be fine. The idea
is to warm the plastic and thus make it more "willing" to be persuaded
to the shape which is required for fitting onto the bike.

The quicker you can try to mount the tank after the tank is removed
from the warm water, the better.


corndog67 03-17-2013 07:18 PM

Ok Guys, today, I set the tank out in the sun, it was about 70 degrees, and it went right back on later this afternoon.

Thanks again.

Oh, by the way, it flat gets it on with the airbox removal and airfilter, and the rejet. Pulls the front wheel off in 3rd gear. Makes a pretty good noise, too. Not sure if the jetting is perfect, only rode it about 10 miles, but it's close.

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