Hi,
I have Safari 40lt tanks on my KTM 990 which have basically been a pain to fit from new. The RH tank fitted ok when new but the LH has always been too big. After having fuel in the tanks they grew even more and it took me a while to work out how to get them back on after I take them off for servicing. It's fairly well known that these Safari tanks "grow". Whilst in India in July 2014 I had to remove the RH tank. It sat in the sun while I worked on the bike. When I went to fit it it had grown so much there was no way it would fit back on so I took it into air-conditioning to cool it down again. I was glad to that when I tried to refit it after it cooled it bolted on very easily. I managed to fit all the bolts back in without the usual struggle. So I would suggest if the tank is hot to cool it before you try to fit it. It may shrink enough as mine did to fit easily.
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