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2010 cafe classic fuel tank removed and now wont fit

victorloia

Just got it firing!
Joined
Feb 20, 2013
Messages
3
Location
Harrison, NY
i just did a canister removal on my 2010 cafe classic. i figured it would be easy to put the fuel tank back on with it bieng one bolt.but the tank will not line up with that bolt hole no matter how much i try.anyone else have this issue :(
 
Check to see if anything is binding (rubber lines, etc), and it seems the rubber bumpers that the tank slides into always can use a little lubrication to help with the task. :pinch:
 
I had a similar problem with my B11. I checked everything four times and couldn't see anything binding. Finally used a large screwdriver and some leverage from the wife and was able to get the bolt to line up enough to catch.
 
Lube the rubber tank pucks and the slots in the tank, Tank is plastic and will expand when the pressure is relieved by taking the tank off. Do have an empty tank while trying to mount it and try to have the tank in a fairly cool environment for a while before attempting to mount it. Shaving some rubber off the pucks might help then there is the BFing screwdriver through the bolt hole as a pry bar.
 
thanks for the suggestions, I did try to lube the bushings and I don't see anything binding it although I don't think the fuel injector line going over the frame backbone is a good design as it looks like its a little flat from the tank. im a mechanic and I have been fixing bikes for over 20 years and I cant believe this is that hard. I will try emptying the tank and try again :eek:
 
Drait had good suggestions; shave the rubber "pucks," add some lube, and lever it in w a large screwdriver.

One time I had to get a second person to help. It is a problem, with no easy solution.

Joe
 
i found a easy one person way that worked like a charm (i will post photos if needed).i found a 8 inch long piece of 2x4 (any size close will do)and a scissor jack from my car.place the 2x4 but up against the back of the frame where the back of your seat locks in lay the scissor jack flat on its side with the bottom against the 2X4 and the top where it has a small curve fits perfectly against the bolt hole tab on the back of the tank.slowly turn the jack until the hole lines up/bolt in done in 3 minutes.im back on the road :D :D :D
 
It's alcohol fuel causing the tank to deform. Back in the day, I had the Centauro tank off for a week or so, and there was *no way* it was going back on. This was a common problem then, and I don't doubt it still is. There were some good suggestions above. I ended up making a stud with about a 10 degree angle on it, taking out the bushing, putting the tank back on, and driving the bushing over the angled stud. Some gave up and didn't put the bushing back on it..
I tried a ratchet tie down strap to try to reform it back to normal without any luck btw..
 
Here is an idea. If the tank has deformed contact Piaggio for a replacement. The manufacturer is responsible for the suitability of the materials used to construct it's fuel tanks. It's well known ethanol destroys plastic fuel tanks.

Vivo
 
I have taken off my tank a few times and found that lifting up the rear of the tank a small amount will make a BIG improvement!

Raise the rear of the tank up 3/16" to 3/8" when trying to thread in the fastener bolt - may have to wiggle a slight amount while trying to start the thread. Works every time for me.
 
i found a easy one person way that worked like a charm (i will post photos if needed).i found a 8 inch long piece of 2x4 (any size close will do)and a scissor jack from my car.place the 2x4 but up against the back of the frame where the back of your seat locks in lay the scissor jack flat on its side with the bottom against the 2X4 and the top where it has a small curve fits perfectly against the bolt hole tab on the back of the tank.slowly turn the jack until the hole lines up/bolt in done in 3 minutes.im back on the road :D :D :D
I have been at it for 3 days and IU think the 2x4 with a hydraulic jack is the answer. Ridiculously hard
I have taken off my tank a few times and found that lifting up the rear of the tank a small amount will make a BIG improvement!

Raise the rear of the tank up 3/16" to 3/8" when trying to thread in the fastener bolt - may have to wiggle a slight amount while trying to start the thread. Works every time for me.
I have taken off my tank a few times and found that lifting up the rear of the tank a small amount will make a BIG improvement!

Raise the rear of the tank up 3/16" to 3/8" when trying to thread in the fastener bolt - may have to wiggle a slight amount while trying to start the thread. Works every time for me.
I have taken off my tank a few times and found that lifting up the rear of the tank a small amount will make a BIG improvement! I will try this as well.
 
i found a easy one person way that worked like a charm (i will post photos if needed).i found a 8 inch long piece of 2x4 (any size close will do)and a scissor jack from my car.place the 2x4 but up against the back of the frame where the back of your seat locks in lay the scissor jack flat on its side with the bottom against the 2X4 and the top where it has a small curve fits perfectly against the bolt hole tab on the back of the tank.slowly turn the jack until the hole lines up/bolt in done in 3 minutes.im back on the road :D :D :D


I use the same technique when necessary.
 
Finally succeeded. Car Jack with two 2x4 worked without the aluminum sleeve. When I was done could not put the leather straps that connect with the horns. No space between gas tank and steering column. A job for another day.

That is not German engineering. It is Italian “make it look great” and dont worry about engineering. I had other projects but damn the bike is good looking.
 
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