Plastic Tank problems: Discussion thread, see info thread sticky for updates

[jgrm1]

drain the gas, open the filler and let it sit for about 1-2 weeks.  they shrink back to size when dry.

I suppose this is good until the next time you splash gas into the tank.

actually, you may be onto something -- the pressure combined with ethanol/gas permeation could be a factor.  moreover, the venting design on the US models is unique to US (and maybe Canada) models due to CARB requirements.

it's still a plastic (flexible) tank.  enough internal pressure pushing out and you will get deformation.  add a penetrating solvent to the mix and the interior becomes even softer/more flexible and pressure can act on that to deform it.

it would explain the type of expansion that's been seen, but i don't think it would happen if it was pressure only -- that plastic should not deform so easily and is rated for pressure (but maybe only external pressure...hmm)

I considered the pinched breather line being a root cause, but doubted the Sport Classics have the same pinch point.  Maybe the do?

I took photos of my findings on my bike, but apparently cannot post them here directly from my hard drive.  I'd love to share them.

-Jeff

[ducatiz]

If you send them to me I can host them.  Photobucket is also an option.  Pm me

[ducatiz]

jgrm1's bike pics  - thumbnails, click for large picture

last one shows the pinched vent line.

[ducpainter]

jgrm1's bike pics  - thumbnails, click for large picture

last one shows the pinched vent line.

<snip>

That looks like the cap area drain, not the vent.

[J.P.]

I've run 2 seperate drain lines from the tank since removing the charcoal can(5/2006), mainly to avoid this kink problem. My tank is as bad as anybody's- doubt any correlation.

[jgrm1]

That looks like the cap area drain, not the vent.

Yep, you are right.  I should have paid more attention to that bright orange sticker under the tank.  The drain line should not affect pressure inside the tank.  I wonder why my tank does build pressure though.  A good place to start is pulling off that emissions canister and associated plumbing. 

-Jeff

[ducpainter]

Yep, you are right.  I should have paid more attention to that bright orange sticker under the tank.  The drain line should not affect pressure inside the tank.  I wonder why my tank does build pressure though.  A good place to start is pulling off that emissions canister and associated plumbing. 

-Jeff

I'd sooner think a cap problem, or the little rubber nub under the cap is blocking the hole in the cap.

If your emissions can is removed remove that black rubber piece too. It has no purpose.

[aglanixp]

I took my 2007 S2R1000 to Battley Cycles in MD this week.  Service guy said no problem, he will start the paperwork.
While looking around I saw a 1098 with an aluminum tank! 
Made a couple of jokes with the salesperson about that tank not expanding.

Would be great to get an aluminum replacement for the monster.
not holding my breath though.

[duccarlos]

My new tank was approved. Lets see how long it takes.

[accrocker]

My tank was approved six months ago....still waiting for it to arrive. I cannot believe how slow the shipping process is. Are they hand carving the nylon tanks now??

[muskrat]

that sucks.  I got mine in two weeks.  check with another dealer just in case yours dropped the ball or call DNA.

[ducatiz]

My tank was approved six months ago....still waiting for it to arrive. I cannot believe how slow the shipping process is. Are they hand carving the nylon tanks now??

what MY and color?

my 05 "Acid Yellow" took longer -- only year they made that color and fairly small number in the first place (<5000 made)

6 months isn't too bad.  just stay in touch with your dealer every month and ask them to double check the ETA.  ducati ships them by boat in a large shipment, and i imagine they aren't quick to make.

[krista]

This is a serious issue because of the fire risk if the tank were to wear all the way through and allow gasoline to spill onto my ignition wiring and hot engine.  Obviously, a fuel leak occurring while riding the motorcycle could result in a crash, injury or death, and property damage.  I also cannot lift the fuel tank as designed by Ducati to service the motorcycle.

I think the fuel tank will break the ignition switch off the frame before it "rubs through" and leaks fuel. The tanks we manufacture are crosslinked polyethylene, aka PEX, not nylon (which is far more dense). The PEX tanks we have are incredibly durable and very very strong. I would imagine nylon to be equally or more strong than what we are accustomed to.

Further, PEX seems somewhat fire-retardant. We are on the wind up to do some more testing as part of some involvement I have with another industry.

My tank was approved six months ago....still waiting for it to arrive. I cannot believe how slow the shipping process is. Are they hand carving the nylon tanks now??

Nylon is difficult to manufacture, likely with many wasted parts. The nylon itself is about $400 per tank to purchase the raw material. Then they get painted and packaged for individual shipment, which means a minimum of 1.5 times the volume the tank occupies is now wasted on packaging. Now to ship only 100 tanks is more volume than a car. They can hire a private jet for a few $10,000 or they can put those and many more tanks in a container and drop it on a ship for a grand.

We have all become spoiled by how manufactured goods materialize out of thin air available at our slightest whim, but one cannot grow nylon tanks from thin air and have those teleported to your doorstep tomorrow (or next week or next month).

Something that really bothers me is how indignant some people are acting. Really? If putting Ducati out of business is that important to you, keep it up. Realistically, there isn't a safety problem; it's a cosmetic issue. Sure, this is a PR nightmare but imho, Ducati is doing far more for us Monster (and Sport Classic) owners than they could be.

Oh yeah, the original red tank on my 2005 S2R800 has a bulge or two and I just don't care. Nor can I be arsed to whinge to NHSTA or my dealer about it.

/rant

[jgrm1]

I think the fuel tank will break the ignition switch off the frame before it "rubs through" and leaks fuel.

Well, if that's all, we are all just being silly.  You guys whose tanks are worn at least through the paint need to quit your whining, go to AutoZone, and find the closest matching touch up paint. 

Something that really bothers me is how indignant some people are acting. Really? If putting Ducati out of business is that important to you, keep it up. Realistically, there isn't a safety problem; it's a cosmetic issue.

...and a functional issue when the tank swells to the point where one can no longer operate the latch to raise their tank for service.  We should all disregard a major flaw and get off Ducati's back.

-Jeff

[He Man]

i dont know who said it was going to rub through and leak thats the most ridiculous thing ive heard. Its been several years since my tank started expanding (which goes back to 08 when i first bought it) and i havent gotten my tank replaced, i have crashed it severla times though.... I Went through the motions and couldnt get it replaced, then DNA siad to go to another dealer blah blah blah, and really i could care less for several reasons.

1) its not going to break anytime soon.
2) The swelling has given me 3/4 gallon of extra gas per fill up (wheres kopfjager to say im bull shitting cause he seems to want to do that all the time)
3) Plastic tanks are can crash several times without denting (and i find the bike or myself going latteral quite a few times to know this)

my MAIN concern is that the tank will expand so much on the bottom that the fuel pump no longer creates a good seal and just seeps gasoline onto my motor...