Struggling ... rear petrol tanks bolts GSA

[Sunny Jim]

Been fettling the 2011 GSA today and given the K&N filter a clean ...the 1200 and GSA look like they're 2 x different jobs altogether with the GSA being somewhat more complicated in that you have to lift the rear of the tank to access the filter housing.
To do this the 2 x rear mounting bolts had to come out and lift the rear of the tank supporting it ...
Job done, filter cleaned and replaced BUT struggling like feck to get the bolts back in to the captive nuts ... just not lining up properly and I don't want any strain on the tank mountings.
Anyone had similar issues or any advice would be greatly received.
Many thanks.

(Typical ...tank is full and I'm trying to avoid removing it )

 

[DrFarkoff]

Try slackening your front tank mounts

You wont do the mounts any harm "as long as you are NOT completely BRUTAL!"

Best advice another pair of hands and a decent torch !

 

[Sunny Jim]

Tried that DrF but they ain't going (threaded the Allen head on one of the bolts now which is going to make this twice the job )

 

[AustinW]

I manage to change my air filter without touching the tank. also a 2011 GSA. Its a bit tight but easily do-able.

To line things up, as DrF says slacken off everything that may be holding the tank in the wrong place and try a screwdriver or something into what you can see of the nut hole and lever it until it aligns. good luck

 

[Bryn]

Did my air filter , and had the same problem, slacken off the front and do a bit of wiggling and you should get them in

 

[Sunny Jim]

Did all the lining up, 2nd pair of hands, loosened everything and ...got no further

It can have a night in the garage and wait a day or two.

Thanks for your input boys - much appreciated

 

[Bryn]

I Found the nearside one was the problem...surprised I got it in judging by the trouble you're having Jim

 

[Pukmeister]

Odd, I never undo the tank to remove my air filter ? Did they redesign the airbox on the twin cam bikes ??

 

[Mallard]

It is never easy to re-align these tanks, and the rear bolts never seem to fit. I have found that it is easier with an empty tank. If the tank is more than half full, not only is it heavy, but it also flexes a lot and makes refitting almost impossible. Least amount of fuel in the tank is the way to go. Makes life a little easier if nothing else.

 

[DrFarkoff]

(threaded the Allen head on one of the bolts now which is going to make this twice the job )

?? Threaded the head??

Do you mean that you have Burred out the Hex recess?

I think you have cross threaded them and tightened them up askew

Get an M8 x 1.25 tap

lift the tank up as far as you can and clear the threads properly and try a standard bolt down it with your fingers, before you allow any load to go on it

 

[Sunny Jim]

Do you mean that you have Burred out the Hex recess?

Yep Doc ... that's the one... I'll be drilling it out and putting a new bolt in... thanks for the heads up on the tap-size. (Almost certain I haven't cross-threaded the bolt but clearly used too much force on it )

As mentioned by Mallard, I don't think a full tank of fuel has helped so I'll be syphoning most of it out to see where that leaves me.

 

[Kenny Rodkiss]

Hi Jim, 2010 twin cam, deffo no need to touch the tank to access the air filter.

 

[Sunny Jim]

Heyup Kenny ... thanks for that ...someone needs to tell Haynes

 

[Montydog]

I have an empty tank if you want to lodge your fuel ️?????

 

[steele01]

I remember when haynes put the wrong torque settings in on one of the manuals oops! haha lesson learn't lol

hope you get it sorted mate if you need a second pair of hands gimme a shout

 

[DrFarkoff]

(Almost certain I haven't cross-threaded the bolt but clearly used too much force on it

Cough Cough We'll see

The upside is that if you "just" have a drill big enough to get the tapered head off you can unscrew with small "Vise" grips

 

[Santa-2512]

Cough Cough We'll see

The upside is that if you "just" have a drill big enough to get the tapered head off you can unscrew with small "Vise" grips

If you can, a pair of good wire cutting pliers, can be used to bite into the hex and head and used to start things moving

 

[Sunny Jim]

All options tried and thank-you for the advice boys...now drilling the bolt out very v e r y v e r y slowly

There's clearly something going on with the metal plate that holds one of the fairing mounting-clips in between the captive nut and tank.

 

[Bendy toy]

The petrol tank expands when full making those bolts a nightmare to fit. They are VERY easy to cross thread. DAMHIK!

I got a pair of longer M8 bolts and turned the threads off the first 8mm. This gives a lead into the female thread of the frame.

 

[Sunny Jim]

Well boys that was a task and a half!

I've eventually managed to drill the offside bolt out and decided not to rely on BMW's captive nut idea so that thread got reemed out too ... longer bolt and nylock nut has resolved that problem!!!

Just got to work on the re-inserting nearside mounting bolt now but won't be rushing at it.

The moral of this story is trifold...

It seems the air filter will come away without undoing the rear tank mounting bolts.

Haynes manuals aren't always right

If you are going to loosen these bolts only do it when your tank is LOW on fuel.

All your advice much appreciated

(Sorry Doc but never found out if I'd knackered the captive nut and the bolt is in bits )