Preparing for our 1000 miles/24 hours ride next month, figured I might just benefit from an extra 4 gallons and in-flight refueling 
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8 gallons, no waiting
- Thread starter bigtex
- Start date
Moz
Cruisin' Guzzisti
ah nice Big Tex B) , give us a ride report later...
Could you give us some details as to how/where you plumbed that in? I have a tourtank that I've been thinking of moving between a couple different bikes using quick disconnects, but not sure where /what line to cut in to, specially the new bikes with the fuel pump inside the tank.
Maybe a pic or two of the connections if it's not too much trouble.
Maybe a pic or two of the connections if it's not too much trouble.
Plumbing took some head scratching, plus this is my first aux tank, so I may have taken a wrong route. But it works just fine after a short shake down cruise yesterday.
I quickly realized there is no way to plumb in to the stock fuel lines on a fuel injected machine, so I went with the idea of in-flight refueling, with the goal of an extra tank that I can use to refill the stock tank. All factory fuel lines and pumps are unchanged.
First, I needed a line from the new tank in to the old tank. With the panels off I saw we have a nice flat section at the top of the plastic tank, so I bought one of these from the local hardware store:
I drilled a hole in the top of the original tank (very slowly, with the shop vacuum surrounding the bit) slightly undersized then threaded this unit into the tank. If I was crossing the Sahara I would also reach inside and get a nut on the other side, but it seems very secure for my purposes. Sorry, forgot to take a picture here, but the main concept was a top entry port through which fuel could drop.
Then I ran some 1/4" ID fuel line down, using the path and clips vacated by the evap cannister lines (long since removed). This line exits by the right rear bag.
I fabricated a plate that uses the stock mounting points and latch of the passenger seat. This gives me a sturdy platform to mount the tank and also positions the tank much lower and more central than the typical rear rack installation.
But this does leave the tank much too low to use gravity to feed the main tank. So I went with a cheapo electrical fuel pump, $29 from Amazon.
For mounting that I looked at all that huge open real estate behind the right pannier. First I made up a plate that bolts to the stock rack using the 2 existing open holes at the top. View from the outside with the bag removed:
To that plate I bolted the fuel pump and a manual shutoff valve. From there the fuel line simply runs up to the tank. At the front base of the tank I installed a CPC quick disconnect so I can yank the tank even when full. View from the rear:
Wiring it all together, I ran a new wire from my existing fuse block to a switch (unused harness from a PIAA light set, includes nifty red/green switch light) and mounted the switch on the front of the right bag (velcro). View from the front:
So, I simply fill it up at gas stops and then whenever the main tank gets low, I reach down and punch the switch and it refills the main tank. I'll probably do it while stopped till I gain some confidence in it, but I don't see any reason I couldn't do it on the run. Obviously it is up to me to shut the pump off when done.
The tank comes off using the stock seat key switch and the fuel line disconnect. The fuel pump plate comes off with 2 screws and one wire disconnect. I'm pretty happy.
Comments and concerns cheerfully encouraged.
I quickly realized there is no way to plumb in to the stock fuel lines on a fuel injected machine, so I went with the idea of in-flight refueling, with the goal of an extra tank that I can use to refill the stock tank. All factory fuel lines and pumps are unchanged.
First, I needed a line from the new tank in to the old tank. With the panels off I saw we have a nice flat section at the top of the plastic tank, so I bought one of these from the local hardware store:
I drilled a hole in the top of the original tank (very slowly, with the shop vacuum surrounding the bit) slightly undersized then threaded this unit into the tank. If I was crossing the Sahara I would also reach inside and get a nut on the other side, but it seems very secure for my purposes. Sorry, forgot to take a picture here, but the main concept was a top entry port through which fuel could drop.
Then I ran some 1/4" ID fuel line down, using the path and clips vacated by the evap cannister lines (long since removed). This line exits by the right rear bag.
I fabricated a plate that uses the stock mounting points and latch of the passenger seat. This gives me a sturdy platform to mount the tank and also positions the tank much lower and more central than the typical rear rack installation.
But this does leave the tank much too low to use gravity to feed the main tank. So I went with a cheapo electrical fuel pump, $29 from Amazon.
For mounting that I looked at all that huge open real estate behind the right pannier. First I made up a plate that bolts to the stock rack using the 2 existing open holes at the top. View from the outside with the bag removed:
To that plate I bolted the fuel pump and a manual shutoff valve. From there the fuel line simply runs up to the tank. At the front base of the tank I installed a CPC quick disconnect so I can yank the tank even when full. View from the rear:
Wiring it all together, I ran a new wire from my existing fuse block to a switch (unused harness from a PIAA light set, includes nifty red/green switch light) and mounted the switch on the front of the right bag (velcro). View from the front:
So, I simply fill it up at gas stops and then whenever the main tank gets low, I reach down and punch the switch and it refills the main tank. I'll probably do it while stopped till I gain some confidence in it, but I don't see any reason I couldn't do it on the run. Obviously it is up to me to shut the pump off when done.
The tank comes off using the stock seat key switch and the fuel line disconnect. The fuel pump plate comes off with 2 screws and one wire disconnect. I'm pretty happy.
Comments and concerns cheerfully encouraged.
ELVISTO
Tuned and Synch'ed
Nice one Bigtex, kept it simple, and easy to revert to standard, like it ,well done, G
WayneOrwig
GT Reference
We need a fuel tank that sits in the space behind the right bag where you put the pump.
Very true, there is easily room for a few gallons there. Of course, then I'd have to figure out where to put the pump:silly:
bigtex wrote:
Actually for the size of that pump, I believe it would fit in the tool box under the pillion??
The gravity issue was the second one I was wondering about, your solution is a good one.
Congrats, Tex, very elegantly done!!!
Actually for the size of that pump, I believe it would fit in the tool box under the pillion??
The gravity issue was the second one I was wondering about, your solution is a good one.
Congrats, Tex, very elegantly done!!!
John in PA wrote:
I think you are exactly right, it would fit just fine. Well, it would if I didn't already use that space for my fuseblock :side:
I think you are exactly right, it would fit just fine. Well, it would if I didn't already use that space for my fuseblock :side:
kwn306
High Miler
Wayne Orwig wrote:
I agree, it's a lot of wasted space. A small fuel pump could reside next to the tool kit and pump the fuel to the main tank as needed or it could be mounted underneath the aux. fuel tank.
I was wondering if one of us would design a tank to fit in that area whether there would be enough interest in a group buy type of deal to help bring the cost down.
Look at the bright side of the equation; if the tank only held 2 gallons it would offset the weight of the muffle on the other side of the bike :woohoo:
I agree, it's a lot of wasted space. A small fuel pump could reside next to the tool kit and pump the fuel to the main tank as needed or it could be mounted underneath the aux. fuel tank.
I was wondering if one of us would design a tank to fit in that area whether there would be enough interest in a group buy type of deal to help bring the cost down.
Look at the bright side of the equation; if the tank only held 2 gallons it would offset the weight of the muffle on the other side of the bike :woohoo:
I was thinking maybe a one gallon RotoPax tank mounted on the top of each sidecase. Or, like Wayne said, mount both on the right side to offset the weight of the muffler.
www.rotopax.com
www.rotopax.com