Changing to a plastic fuel tank?

[Phatty]

I notice the later model (old shape) Monsters have plastic fuel tanks.

From what I've seen it looks like the fuel pump and sender fits from underneath rather than from through the filler neck.

Could I fit a later tank and pump and sender on an earlier fuel injected Monster?

[pooh]

Yes I've swapped the tanks on my 2001 900 and my wife's 2004 620 from steel to plastic. Other than the tank and pump assembly you will need a rear tank bracket and dependant on the fuel pump a couple of quick couplers for the fuel lines everything else swaps across.

Ian

[Nickj]

Don't forget to get a spare tank for when your first replacement melts :thumbsup:

[pooh]

Has anybody in the UK had problems with tanks melting or is it just in the USA?

Ian

[gary tompkins]

Yes a few have had problems

Tanks don't melt but the plastic does get attacked by the Ethanol/Water content in some fuel mixes. This causes the plastic tanks to swell and distort out of shape. Some have been replaced in Europe, and plenty have been replaced by Ducati in USA where a class action lawsuit has been filed for substandard tanks. I've heard that Ducati are looking to replace many of these with steel alternatives if/when available.

This could become a much bigger problem in the UK if the Ethanol content in some petrol mixes increases over the current 5%

http://deformedfueltanks.com/

http://www.youtube.com/watch?v=zeqjOVjgZmg

[utopia]

Rac3r had problems with a swollen plastic tank.

[rac3r]

Yep, here are some pics

http://www.ukmonster.co.uk/monster/showthread.php?t=41774

[pooh]

Any idea which fuels to stay away from or is it a case of potluck

Ian

[rac3r]

Well I found out about the swelling just after I had bought the bike, it had been left unused for about a year. As long as you use the bike regularly then you should be okay but if you leave it sitting for a while then you might have to think about what fuels you use.

Someone else should be able to point out which ones to use

[pooh]

Shouldn't have a problem then my bike is used most days.

Ian

[Nickj]

Any idea which fuels to stay away from or is it a case of potluck

Ian

Unfortunately it isn't that simple :( nearly all RON97 blend fuel has up to 5% bio-ethanol already, that's the E5 fuel. Usually it's flagged but it isn'y obvious sometimes. This is already causing problems.
The fuel itself has a much more limited storage life, a few weeks standing see's the volatility drop significantly and the ethanol attacking things like non-synthetic rubber and plastics.
In the near future in a bow to the green wing 07RON fuel will be able to have up to 10% bio-ethanol added which will just intensify the issues. Ethanol is also extremely good at holding water and frequently fuel with a higher ethanol content contains more water. Not good news for the older carbie monsters.
In the states where this tank deformation has been really noted they tend to have winter and summer blends of fue with different levels of ethanoll. The content is allowed to be up to 10% from a base of 5.9% BUT doesn't have to be declared at the pump so even if they are aware of the potential problems they can't always avoid getting the wrong fuel.

[Trent]

Don't the steel fuel tank models have a fuel pressure regulator bolted to the throttle bodies? - whereas the plastic tank models don't?

I assume that the plastic tank system has an in-built pressure regulator as opposed to the external one for the steel tank model - I also assume fitting a plastic tank would require you to remove this external regulator?

Anyone know for sure?

I want to do the opposite to Phatty - I want to remove a plastic tank (it's swollen up and doesn't fit properly any more) and replace it with a steel tank.

[gary tompkins]

Any idea which fuels to stay away from or is it a case of potluck

Ian

http://www.pembleton.co.uk/ePAG/ePAG41/ethanol.html

http://en.wikipedia.org/wiki/Ethanol_fuel

Super unleaded contains about 5% Ethanol, as do some own brands at supermarkets. There's a push to increase this across the board to between 5-10% by 2013. Plastic tanks are not the only issue as Ethanol also attacks some metal components in fuel systems, hoses and seals.

http://www.telegraph.co.uk/motoring/classiccars/9108430/The-ethanol-threat-to-classic-cars-and-bikes.html

[Phatty]

Sounds like a whole world of **** really. No wonder there are so many of them on eBay.

Think I'll keep searching for a steel one.

[jerry]

over 45,000 plastic tanks replaced already under warranty in USA unfortunately the replacements also fail !!!!!!!!!!!!the Yanks have mandatory E10 which is worse then any supemarket E5 sold in UK at present but when EUSSR rules that we must us E10 then tank faliure will explode pardon the pun.

[pooh]

Trent
I have fitted plastic tanks to to my M900ie and the wifes M620ie both previously had steel tanks I have not touched the pressure regulator on the throttle bodies and all works fine.

Ian

[Duc mad]

has there been any issues with tank covers and luggage?