Ducati spreading plastic tank problem

Ducati tank issue - deformed gas tank, originally uploaded by achung_123.

From 2006 onward Ducati has been using plastic tank in their models, and since then there been a lot of complains about tank spreading issues - specifically on Monster and Classic, and few cases of Superbikes. Tank problem varies case by case - from spreading as much as 2" per side, to uneven deformation and anything in between. The odd thing is it only happens in the US models. Like most riders suspect, it is the ethanol added in the fuel reacts with the plastic tank and causes the deformation. Most tanks, like mine, will 'settle' in time and it won't spread any further. In my case, the spread continues since I bought the bike used back in June 2008 with 4.2k miles on it, and finally stop some time last year. No one would notice the problem unless study it closely; but the spreading could possibly cause deadly accident if the tank comes loss from the brackets during the high speed ride.

There are few solutions out there - the cheapest way is adding washer between the frame and the tank brackets to make up the spread space (which is what I did - 1/4" added per side). Just make sure you use a longer bolts and the tank brackets are secure.

The best and the most expensive way to resolve this problem is replacing the tank. But just like another motorcycle, tank probably is the third most expensive parts beside the engine and the frame. In this case, a new Sport Classic tanks costs $1900 USD. Spread tank problem will be taken care of if your bike is under still warranty. In California, gas tank is part of the emission system, which the State requires all manufacture offers 5 years warranty - that's how I got a replacement. In fact, I have just received a call from Ace Motorsports telling me my new tank has arrived for replacement! As for other states, DNA (Ducati North America) may replace it at "good will" - meaning that it is a case by case situation depend on how bad it spread...

For general info of the tank spread issue, check out this Ducati MS forums post. For out of warranty tank issue, check out this post.

Will post picture once the new tank is installed! Can't wait!