Hmm a problem with my 09 450

tim507 · Oct 6, 2009

I decided it was time to take the tank off and explore some. I have been very kind to my bike......with recession I have needed to spend more time paying attention to my business. Oh well that is how I pay for these two wheel treats

The problem, page 65 of the manual shows that you must remove six torx bolts ( 3 per side) from the subframe main member....well the two middle ones (one each side) spin the insert into the tank..... :evil:

.....now as I type this I recall maybe seeing something posted here......what say you all..........

Tim

nsman · Oct 6, 2009

I know this is after the fact but you can avoid this by simply removing the subframe and tank as a unit.

tim507 · Oct 6, 2009

With the wiring harness ending in the battery and all, that concept might be a bit challenging. The goal is to have it correct...the only work around we are stuck with is Micro Soft Problems :twisted: :roll:

My guess is to drain the tank, cut out the corrupt part of the tank, send to Berg USA for a new tank 8O :?

I tried a blade screwdriver between the subframe and the tank on to the insert, but the grip into the tank is already Kaput, and the low grade loctite they used said no way Jose........assembly was to aggressive or the insert was to weak.............

berger · Oct 6, 2009

If you look you will probably see that the torx bolt on the other side spins at the same time as they both go into the same dowell through the tank.
If you had 2 torx bits you could hold one side while loosening the other.
The other option is that there are supposedly flats on the dowell. If you had a thin wrench you could slide between the tank and subframe and hold the dowell.

All of this has been told to me, as i have not had the guts or ambition to remove my tank yet. I have though encountered the spinning torx bolts.

tim507 · Oct 6, 2009

The thin wrench would need to be quite a "wench" and really anorexic :twisted:

I will look and see if the other side spins.....if one side comes loose the then stud should be able to be pulled through and a bit if heat and she can be corrected.

Rory is in Portugal and picking up his 570 Wednesday, i will ask him to talk to Roland or David Larsen about this very issue....facts from the RD team perhaps

omo · Oct 6, 2009

tank

You can use one torxbit on each side, one will come out, then you use a 13mm wrench on that side as the plastic frame then will be easy to bend out a bit.

The way I do it is that i take out the two bolts in front, and the two in the rear and let the plasticpiece follow the tank out. Not the compleate subframe, just the black plastic one at the top.

NKW570 · Oct 7, 2009

Re: RE: Hmm a problem with my 09 450

nsman said:
I know this is after the fact but you can avoid this by simply removing the subframe and tank as a unit.

+1. Thats the way i did it when i first pulled the bike apart.
No reason to touch those bolts and im glad i didnt looking at the hassle they cause.
i was lucky i guess, but its good info for others about to strip the bike down.

tim507 · Oct 9, 2009

Got those devils out.........bought two new T45 Torx with 1/2" drive....used a Dewalt battery impact wrench on one side and a big *** breaker bar on the other side. One side came out, then I used a 8 mm bolt about 2" long and with a big washer and two 8mm nuts to lock the insert against the subframe, then took the impact wrench to the other side....used some of the kings langauge some extra effort to the double lcok nuts and the other one jumped out...yay

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Hmm a problem with my 09 450

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