Norge gas tank too long

[Kaladin]

So evidently the gas tank has swollen because when I try to get it back on the screw holes won't line up.   Any clever ideas on how to re-install it?
I also need to slide it back at the DMV so they can read the VIN number. . .
And then re-install it in the parking lot.

thanks
mark

[blackcat]

Mine hasn’t been able to bolt in place for years and I tried cutting down the rubber grommets but it didn’t help, maybe I need to do it again. I’ve been told that draining the tank and letting it sit for a few months will shrink the tank and you’d have to use non ethanol gas to keep it from expanding again; it’s easy to get non ethanol where I live but that isn’t always the case, especially on a road trip.

In the meantime I just use a large zip tie to keep it in place in case of an accident.

[Dirk_S]

Drain the tank and place it in a freezer overnight?

[PJPR01]

Get a medium size Philips screwdriver with a long handle, insert it into the tank hole and thru the threaded frame and firmly push forward, while sitting on the bike with your knees pressed on the tank pushing it forward a bit.

Remove the screwdriver while keeping the pressure on the tank with your knees and thread in the screw.

Presumably you are fully aligned on the rubber grommets at the front of the tank?

[Kaladin]

Get a medium size Philips screwdriver with a long handle, insert it into the tank hole and thru the threaded frame and firmly push forward, while sitting on the bike with your knees pressed on the tank pushing it forward a bit.

Remove the screwdriver while keeping the pressure on the tank with your knees and thread in the screw.

Presumably you are fully aligned on the rubber grommets at the front of the tank?

I tried that, the tank is too long. 
I think leaving it off the bike for a week was the wrong thing to do.   
Maybe the zip tie will work at least to get it registered. . .

[SemperVee]

learned this on my first Norge, why she only gets expensive Mermaid tears (Ethanol free) for go juice.  I agree that probably shaving the front doughnuts might be the way "forward" in this case. YMMV..

[Stretch]

Drain the tank and place it in a freezer overnight?

An excellent idea, Dirk!

If Kaladin ain't married, it might just work!   

                                     -Stretch

[Kaladin]

I am married, but I have a temperature chamber at work.  Should I bake out the water in the nylon or freeze it?

[guzzisteve]

I used to have 2 pieces of 1 by(3/4") in my box at work. Put together, 1 on fuel tank & 1 on the ledge on fender would make a small tent shape. If you push down on the peak yuo move it right up in place, super easy. You could also cut the rubber pucks down. I found they go back to the enlarged size as soon you put in fuel unless coating and it still a waste of time.

[Mike Craven]

Someone needs to (!) come up with a fabricated offset stud or clamp for mature tanks.
-Mike-

[PJPR01]

I tried that, the tank is too long. 
I think leaving it off the bike for a week was the wrong thing to do.   
Maybe the zip tie will work at least to get it registered. . .

I've had the tank off for a week or more in the past and just used this simple method with no issues. 

By any chance did you take out the airbox or anything else that might be blocking the tank from fitting forward...100% sure the tank is set onto the rubber grommets and is not jammed somehow?

[Wayne Orwig]

Drain it, plug the holes, apply a light vacuum. That may pull the moisture out plus shrink it.

[Gliderjohn]

So evidently the gas tank has swollen because when I try to get it back on the screw holes won't line up.   Any clever ideas on how to re-install it?
I also need to slide it back at the DMV so they can read the VIN number. . .
And then re-install it in the parking lot.

thanks
mark

Can't speak for the first gen Norge but with a 2011 Norge two people can read the VIN on the frame neck by having one person look up from below using a small flash light while the other holds back wiring. That will get some of the numbers, the do the same looking down from above for the rest of the numbers. At first I was going to also loosen and move the tank back but the DMV office manager said I could not do that due to "altering the bike" which was not allowed. They have the private for profit tag offices available here. Went to one of them and did as described above because the worker knew how.
GliderJohn.

[nwguy]

This is one of the two reasons I sold my first gen Ducati Multistrada. It had a plastic tank about 4 feet long (see pic below). There was a recall and I did get a new tank out of it. Then I found out that many owners had 2 tanks and left one to dry out in the garage until they needed to remove the other tank from the bike. Then they'd swap. Ridiculous.

The other reason I sold it was the frequent and expensive valve adjustments (bucket and shim) vs. doing my own on my old Norge or current Bassa. My old Norge tank did swell too.

[Kaladin]

Drain it, plug the holes, apply a light vacuum. That may pull the moisture out plus shrink it.

I also have a vacuum oven, but it won't fit.

[Motormike]

This is one of the two reasons I sold my first gen Ducati Multistrada. It had a plastic tank about 4 feet long (see pic below).

Yep, I feel your pain.  Still have a Ducati Multistrada fuel tank in my attic.  Can't bring myself to toss it, even though the bike is long gone.  I gave up on the whole plastic tank/ethanol fiasco a few years back and sold most all (two Ducati's, one V11 Guzzi) the motorcycles in my modest collection that had PA6 nylon fuel tanks all made by Acerbus. Still have a Griso with a nylon tank, but am religious about only running non-ethanol gas in it.  The whole stupid E10 business has given me a real obsession about using non-ethanol gas in my bikes. 

[PJPR01]

Non Ethanol is the main reason I go to Bucee's to fill up with 91 Non Ethanol...makes the bike run better and obviously seems to be helping with any tank expansion issues too.

[MGrego]

I used a scissor jack between the tank and the frame, I think I had to use a small block of wood on the tank side.  Turn the screw till the holes line up, easy. 

[brider]

I've had to remove my tank a half dozen times and the long screwdriver probably method has always worked. The holes never completely line up, but with enough angle of the bolt and a good socket I can get it started (probably cross-threaded) and then work the bolt to vertical as it screws in farther. HOWEVER, I may try that ingenious zip tie method next time if I can't get it, there are some zip-ties that are major beefy, would serve the purpose well.

[SIR REAL ED]

After you guys have managed to successfully shrink an expanded gas tank, have any of you sealed the gas tank to prevent future expansion?

IIRC, Caswell's Dragon's Blood gas tank sealant is recommended for "plastic" gas tanks.

[Dirk_S]

IIRC, Caswell's Dragon's Blood gas tank sealant is recommended for "plastic" gas tanks.

For clarification, I think you’re referring to Caswell’s two-part epoxy tank sealer; Dragon’s Blood is one of the colors.

https://caswellplating.com/caswell-epoxy-gas-tank-sealer-car-tanks-up-to-20-gal-1-quart.html?srsltid=AfmBOopUSmpc8GsXoW-57vpfj5eBaeKP3Ak0UQ0hfWMBqc1YlbBUuSmW

[Kaladin]

I used a scissor jack between the tank and the frame, I think I had to use a small block of wood on the tank side.  Turn the screw till the holes line up, easy. 

Success, I found a small bottle jack that not only fit and was red like my bike.

[Kaladin]

Sorry, for some reason the web page rotated  the image.  This one might be more understandable.
The hydraulic jack needs to be rotated so the oil can reach the actuating  piston.

[Motormike]

Success, I found a small bottle jack that not only fit and was red like my bike.

Having to use a hydraulic jack to put fuel tanks back on? I mean, seriously folks!? I guess it beats an unusable bike.  It's a good thing those nylon fuel tanks have some flex to them.

[Kaladin]

Having to use a hydraulic jack to put fuel tanks back on? I mean, seriously folks!? I guess it beats an unusable bike.  It's a good thing those nylon fuel tanks have some flex to them.

They must have some flex to them, since they fit nicely before taking out the bolt.  There also might be some extra compression of the front mounting posts.

[Moparnut72]

I have never been in a situation like this but to me I would probably figure out a way to modify the mounting rather than stressing the tank.
kk

[DoubleGuzzi]

Same thing happened with my Triumph 955 Sprint ST; car jack and a block of wood to the rescue. There is a risk of rupturing the tank though.   

[Abbienormal]

I've had this problem more on the 2012 I had than both my 2007's one of which I currently am riding.  If it is not a lot then I use 2 round rods, punches, screwdrivers or whatever.  Put them on either side of where the bolt goes, slip them into the frame and push the tank forward.  On my 2012 it swelled too much for this to work so I took a either a file or dremel, I forget, and ground the hole so it was enlongated and I could put the tank on.  There was enough just plastic and not tank to do that in front of the hole.