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V7 Classic/Café/Racer under-tank issues.

Carl Allison

Cruisin' Guzzisti
GT Famiglia
Joined
Jan 6, 2009
Messages
118
Location
Payson
I removed the tank of my V7 Café this afternoon to add wiring for a set of Fiamm horns. When I finally got the tank off (what a pita!) I was presented with the following views (first and third images). The bike has 5000+ miles on it. There is an appreciable amount of chafing going on where the wiring harness is flat up against the underside of the fuel tank.

Note the green tank material deposited on the wiring harness below the coil. That is material rubbed off of the underside of the fuel tank. The harness is hard up against the coil with insufficient space to clear the underside of the fuel tank. (The yellow/brown and white wires are wiring that I've added for a horn relay under the left side cover.)


Here I've moved the bend in the harness a tad further aft and tie-wrapped the lower bend further inboard of the frame rail.



Note the green tank material deposited on the folded over part of the harness lead going to the connector tie-wrapped to the bottom fram rail.


Here I've snugged wiring lead up against the top frame tube and tie-wrapped it in place.


Here, the tank fuel vent line was crimped so badly beneath the tank that it became brittle and broke. All I could do here at the moment, was cut out the bad section, re-route and stretch the tube and finagle it back into place when I put the tank back on.


As a side note, the tank fits so snugly on the front mount that to engage the rear tank bolt requires a monumental amount of pressure be exerted on the tank to push it forward enough to allow the bolt to be threaded. In the near future, I will remove some material from the very rear portion of the tank rubber snubbers at the front tank mount so that less pressure is required. Somehow, I don't think that the amount of stress being applied to the bottom of the tank from the mounts is a positive thing.
 
"As a side note, the tank fits so snugly on the front mount that to engage the rear tank bolt requires a monumental amount of pressure be exerted on the tank to push it forward enough to allow the bolt to be threaded. In the near future, I will remove some material from the very rear portion of the tank rubber snubbers at the front tank mount so that less pressure is required. Somehow, I don't think that the amount of stress being applied to the bottom of the tank from the mounts is a positive thing...."

That's exactly the same problem I had when I partially removed the tank on my V7 Classic. I was pushing so hard against the back of the tank trying to get that mounting bolt to go into its threaded hole without cocking, I thought I would surely crack or damage the tank. I removed the two rubber bungs that the front of the tank slides over, and shaved off a bit off material at the rearward facing surfaces, to allow a little more frontwards movement of the tank. This allowed me get the tank back on. I feel as you do, that the tank being subjected to that much continuous pressure, could eventually lead to trouble. Before I did this, that bolt and the hole its supposed to go into, were at least 1/8 inch off. I'm wondering if this is common, or maybe just a few bikes have this problem.
 
Same thing with mine. Had to shave the rubber mounts and have the girlfriend help me push the tank into place.

Someone made a suggestion (was it Carl?) that the jig at the factory must be out of adjustment. Good idea.
 
Don't know if I've got the wrong end of the stick here as I haven't tried to take the tank off yet. In the past I've had many petrol tanks that are held on by U shaped tank fittings sliding on to rubber bungs attached to the frame then held in place with a bolt through a tab on the seat end. To get the tank to slip into place easily sometimes required a dab of liquid soap on the rubbers, nothing more. As I say, I may have misunderstood the problem as described if so, sorry for butting in.
 
This thread has been dead for a bit, but I just bought a 2010 cafe classic and I just found out how awful the tank fitting is... It has to be from the notorious tank expanding problem that these things have. I protected my tank with a towel and wrapped a ratchet strap around the back of the tank and the forks and had to wench it down way harder then I should've had to to get it to line up. Now the tank is too wide to fit on the front mounts. I'm extremely pissed.
 
This thread has been dead for a bit, but I just bought a 2010 cafe classic and I just found out how awful the tank fitting is... It has to be from the notorious tank expanding problem that these things have. I protected my tank with a towel and wrapped a ratchet strap around the back of the tank and the forks and had to wench it down way harder then I should've had to to get it to line up. Now the tank is too wide to fit on the front mounts. I'm extremely pissed.

I feel your pain.

I had the same issues with the plastic tank on my 2001 Triumph Sprint ST...f'n ethanol.
 
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