After returning from my first trip with new motorcycle (KTM 690E) I noticed the following problems: Wear of upper tank bolts, one bolt was scratched the fuel hose and there was significant amount of dirt in the fuel tank.

Soluttinns are as follows:

I hope that Billet Filler Adaptor (sold by rally raid) would solve the issue.

I clamped fuel line with larger clamps to ensure the distance from the upper tank bolt.

Upper tank bolt wear is a complex problem. Since the vibration at the contact of frame and gas tank can not be eliminated, the new (better, harder) bolts will eventually wear too. The answer lies in the simplification of upper tank bolts in such a way that repair can be done anywhere in the world. Local metal industry workers made me a custom sleeve, and the remaining parts (bolt and washer) are standard.




The next step is to transfer weight from the rear of the motorcycle forward and relieve weight on the subframe. One solution is Aqualine Safari Fuel tank With this tank some 14 kg of weight is transferred to the front of the motorcycle. This solution was not interesting for me for several reasons.

If there is necessary to remove the motorcycle luggage due to the difficult terrain or obstacles on the way tank stays on the motorcycle while jerry cans can be removed and cary over the obstacle.
In the case of perforation of the tank, I will spend the rest of the way without fuel reserve, while new jerry cans can be purchased.

There is safety issue. If it is written that they are not street legal, it means they do not meet certain conditions and standards required by the traffic legislation. In the case of traffic accidents those tanks can become dangerous. In the event of spillage of fuel, fuel will be spilled over the rider and the ignition can be fatal. If jerry can spills, fuel will likely be spilled behind motorcycle. By putting the sign "not street legal" company is not liable for any injuries on the road.

For the next trip I will transfere some load from rear by fixing tool tube on skid plate and with some saddle bags mounted over radiator protection.