Help with tank! Not fitting back! - 600RR.net
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post #1 of 29 (permalink) Old 08-09-2010, 10:00 PM Thread Starter
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Help with tank! Not fitting back!

I took my rr apart so I could do the air box mod and replace the factory filter with the BMC race filter...Well everything is back together, but the tank fairing will not fit properly...Ive tried many methods that I have searched on this forum, but none are working.


1) Ive tried taking the cap off and mounting the fairing and then replacing the cap.
2) Ive put grease on the seal and tried shifting the fairing back and forth
3) Ive put tape on the inside seal and tried putting the fairing on and then removing the tape


ALL the above ended up in the same situation and its starting to frustrate me pretty bad. The tank will just not fit properly on the seal. The back (closer to the seat) is fitted correctly, but the top (near the handlebars) it is not flush with the tank cap. Its about 1/4" gap and I can not get it to go down.

Since thats that mounting right, my two upper fairings are not snapping in to the tank and causing a gap and its driving me nuts!

Please someone help bc I take this bish to Honda.

Here are the pics:
Notice the Gap?


Hard to tell, but the upper fairing will not snap in completely and stay attached to tank fairing...Pic shows gap where they meet

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp

Last edited by Bpotter22; 08-10-2010 at 04:51 PM.
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post #2 of 29 (permalink) Old 08-10-2010, 12:04 AM
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Is your actual gas tank seated down properly? You could have got a hose pinched or something under there that is lifting the tank just enough to set you off. That would be my guess.
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post #3 of 29 (permalink) Old 08-10-2010, 12:11 AM Thread Starter
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I believe everything is good under there...do the tanks have any play in them once they are bolted down? After I bolted it back, I could lift it slightly and it seems the bracket holding it is made to have a little bit of play in it...The bolts were not getting any tighter...

I just dont think I should be having this much trouble with it.

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'05 Mustang GT 324ci supercharged - 750+whp
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post #4 of 29 (permalink) Old 08-10-2010, 12:15 AM
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ive had to lift it up due to hoses being caught adn thats why ti wasnt seating properly
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post #5 of 29 (permalink) Old 08-10-2010, 12:19 AM Thread Starter
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hmmm...well i guess I will be taking it apart yet again tomorrow..ughh

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'05 Mustang GT 324ci supercharged - 750+whp
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post #6 of 29 (permalink) Old 08-10-2010, 12:48 AM
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popping the tank off doesnt take that long. Just lift it up and make sure the hoses are in order. You dont even have to take the two bolts off the rear of the tank, just pivot it up.
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post #7 of 29 (permalink) Old 08-10-2010, 12:55 AM Thread Starter
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i just dont see how that could cause the fairing to not go on...The tank is bolted in the way its supposed too. If a hose was wedged in, I couldnt bolt the tank down. The fairing also bolts into place but just wont go over the tank cap all the way.

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #8 of 29 (permalink) Old 08-10-2010, 04:13 PM Thread Starter
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Any more ideas? I took the seal completely off and tried putting tank fairing on, but it still left a gap!? What gives? It was on there perfect before filter, but now it wont go on at all...The gap isnt what bothers me...its the dang upper fairings that wont stay hooked in to the tank fairing...

I NEED HELP!

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #9 of 29 (permalink) Old 08-10-2010, 04:33 PM
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not just the fairing, did you take the whole tank off? there is obviously some difference in the way the tank is sitting and the way the tank fairing is sitting.
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post #10 of 29 (permalink) Old 08-10-2010, 04:46 PM Thread Starter
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I took it all apart again today...Nothing is in the way...Also, took it to Honda and they just scratched their head and said "hmmmm..I dont know. Good Luck"


Here are the pics:
Notice the Gap?


Hard to tell, but the upper fairing will not snap in completely and stay attached to tank fairing...Pic shows gap where they meet

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp

Last edited by Bpotter22; 08-10-2010 at 04:52 PM.
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post #11 of 29 (permalink) Old 08-10-2010, 04:57 PM
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What order are you trying to put them on?
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post #12 of 29 (permalink) Old 08-10-2010, 05:07 PM Thread Starter
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Originally Posted by sean.landon View Post
What order are you trying to put them on?

Mounting the tank, then mounting the tank fairing, then the upper fairing...Thats the only way to do it, because you will not be able to bolt in certain bolts if you do it any other way.

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post #13 of 29 (permalink) Old 08-10-2010, 05:13 PM
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Quote:
Originally Posted by Bpotter22 View Post
Mounting the tank, then mounting the tank fairing, then the upper fairing...Thats the only way to do it, because you will not be able to bolt in certain bolts if you do it any other way.


lol i know this... just making sure you aren't making a simple mistake like i always catch myself doing. Good luck man!
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post #14 of 29 (permalink) Old 08-10-2010, 07:07 PM
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I am not sure how but from your picture i can tell you the tank itself is sitting up to high on the front side (side closest to the handlebars). The back of the tank obviously cant move but something is keeping the tank high but just a couple degrees. I cant tell you any more without farting with it myself.

The other thing is with fairings sometimes you gotta be a little firm with them. I know I am stating the obvious but have you tried just pressing down really hard on top the tank right there to get it to seat?

Last edited by buechelr; 08-10-2010 at 07:09 PM.
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post #15 of 29 (permalink) Old 08-10-2010, 07:20 PM
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I believe there is a rubber seal on that goes around the metal gas cap. When I took mine off I had trouble with this fitting so I removed the rubber cover (I use aftermarket fairings so fitment was always an issue).

In you case, does the rubber o-ring cause the plastic tank from coming all the way down? If it does you may need to use a little soapy water to make the ring slip down easier.
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post #16 of 29 (permalink) Old 08-10-2010, 08:20 PM
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Dude - if all 4 bolts go in, your tank is fine.
Your plastic tank COVER is the issue.
And it looks decently centered, but there's a thick rubber ring around the filler cap as noted, which you need to really frig with to get the plastic around it, without it bunching up or twisting in there (it keeps gas and water from getting underneath, it's important to get it right!).

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post #17 of 29 (permalink) Old 08-10-2010, 09:11 PM
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bit of brute strength and shear ignorance always seems to do the trick !
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post #18 of 29 (permalink) Old 08-10-2010, 09:28 PM Thread Starter
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Quote:
Originally Posted by supercliff View Post
I believe there is a rubber seal on that goes around the metal gas cap. When I took mine off I had trouble with this fitting so I removed the rubber cover (I use aftermarket fairings so fitment was always an issue).

In you case, does the rubber o-ring cause the plastic tank from coming all the way down? If it does you may need to use a little soapy water to make the ring slip down easier.

Ive tried every trick to get it to fit...Nothing it letting it go down...It will go down but it comes right back up...

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #19 of 29 (permalink) Old 08-10-2010, 09:30 PM Thread Starter
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Quote:
Originally Posted by z537z View Post

Dude - if all 4 bolts go in, your tank is fine.
Your plastic tank COVER is the issue.
And it looks decently centered, but there's a thick rubber ring around the filler cap as noted, which you need to really frig with to get the plastic around it, without it bunching up or twisting in there (it keeps gas and water from getting underneath, it's important to get it right!).

As noted in the first post and recent ones, I have tried, tried, and tried some more to fit the cover over the seal...Ive worked on it 3 days in a row now with no luck...Maybe I need to mess with it some more.

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'05 Mustang GT 324ci supercharged - 750+whp
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post #20 of 29 (permalink) Old 08-10-2010, 10:49 PM
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My suggestions (outside of the obligatory "frig with it until it's in there or totally destroyed" )
1. Schooze a little grease or silicone oil on the rubber piece
2. Wiggle the tank cover striaght down onto it (as much as possible), twisting if you can to the rubber from folding over.
3. Once you get it started decently, you have to manipulate the rubber piece with a small instrument (flat, no sharp edges - such as a thin flathead screwdriver w/ masking tape over it, or any random plastic thingy you find around) to untwist/unjam it in the right places, then push the cover the rest of the way down.
4. Gentle thunking by hand is always helpful.

It took me a few tries to do mine last time, and I ended up chipping a little paint off the plastic. I despise plastic bodywork!

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post #21 of 29 (permalink) Old 08-11-2010, 05:53 AM
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Take the seal off completely and put the cover back on, if it goes on properly then you know what your problem is.
Check out my DIY here: https://www.600rr.net/vb/showthread.php?t=192860
It has my solution to getting that damn seal sitting right and a few other good suggestions from other guys as well.
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post #22 of 29 (permalink) Old 08-11-2010, 11:01 AM Thread Starter
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Quote:
Originally Posted by Nico View Post
Take the seal off completely and put the cover back on, if it goes on properly then you know what your problem is.
Check out my DIY here: https://www.600rr.net/vb/showthread.php?t=192860
It has my solution to getting that damn seal sitting right and a few other good suggestions from other guys as well.

Thanks. I actually read that before I took it off.. I figured if I already knew how to put it back on, I would be fine from your DIY...But still no hope on getting it fixed...Im completely out of ideas as I have tried everything.

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #23 of 29 (permalink) Old 08-11-2010, 11:09 AM
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Where the tank mounts to the frame on the forward most part, are the rubber grommets and metal washers still there? If you have one of the washers tilted wrong or the metal parts completely missing, the tank wont fit right.

Also, any problem at the top of the airbox? Something that would be sticking up higher then normal?

If all of that is fine, you just need to do what everyone else does. Lube the seal, and push down on it...or try putting it on from the front first.
post #24 of 29 (permalink) Old 08-11-2010, 04:56 PM Thread Starter
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Day 4: took everything off again...Still no solution.

I have checked everything again to make sure everything has been bolted back properly from the air filter change. Air box, wiring harnesses, wires, etc are all in the proper locations. The tank is bolted down correctly and does have the washers in place. I can see the seal all the way around the tank cap and it appears fine. I can push down on the fairing with force to get it where it needs to be but it comes right back up. I went back today and cleaned up all the wiring from the DDM HID install and that seemed to help a little bit but its still not perfect.

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #25 of 29 (permalink) Old 08-11-2010, 05:00 PM Thread Starter
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Quote:
Originally Posted by Demented View Post
Where the tank mounts to the frame on the forward most part, are the rubber grommets and metal washers still there? If you have one of the washers tilted wrong or the metal parts completely missing, the tank wont fit right.

Also, any problem at the top of the airbox? Something that would be sticking up higher then normal?

If all of that is fine, you just need to do what everyone else does. Lube the seal, and push down on it...or try putting it on from the front first.
Yes, both washers are there. What do you mean tilted the wrong way? They are flat washers so how can they be tilted wrong? Also, is the tank supposed to have any flex in it? After its bolted down, I can still lift up on it and it will come up about 1/8"-1/4". I believe its supposed to and thats what the rubber grommets are for.

Also, Ive checked the air box, etc and there are no problems there. I just ordered a new seal so I will see if there is something wrong with my seal..It was only $5.

Can you take a pic of your tank cap from an angle that shows how the fairing is supposed to look when installed properly. Kind of how I took a pic of mine in my earlier posts.

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #26 of 29 (permalink) Old 08-11-2010, 05:09 PM
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Have you removed the cap/filler assembly?
What about the steering stabilizer?
Tried with the side cowling removed?

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Unfortunately bikes fall over. It's in their nature.
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post #27 of 29 (permalink) Old 08-11-2010, 05:20 PM Thread Starter
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Originally Posted by MikeyP View Post
Have you removed the cap/filler assembly?
What about the steering stabilizer?
Tried with the side cowling removed?

No, no, yes


Right now, I have just the lower fairings on. Tried putting the tank fairing on without the seal and its the same result. Ive checked and there is nothing in the way so this is getting the best of me...

'07 CBR600RR
'05 Mustang GT 324ci supercharged - 750+whp
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post #28 of 29 (permalink) Old 08-11-2010, 05:30 PM Thread Starter
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OMG!!! I got it!!!! WOOHOOOOOO! I feel like the guy from the Double Rainbow song! lol


It was my freaking harness on top of my air box...It was mounted but incorrectly! It was just sitting up high enough to cause the front not to go down!


WOOHOOOO!!!!!

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post #29 of 29 (permalink) Old 08-11-2010, 05:32 PM
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Edit: Nevermind.
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