42 Litre Touratech Fuel Tank

The fuel tank was added to provide the bike with better range to better equipe us in regions where fuel isn't readily available. When riding tracks or sand the mpg's the bike returns goes whey down as the bike revs higher and gets less traction. My innitial thoughts were "blimey it's huge", but after riding with it for a while you become accustomed and it doesn't adverlsy effect the bikes handling.		  
R1100/1150GS 42L tank - instlation tips  
 

1. Begin by having as little fuel as possible in the stock tank. This will save you time and effort later in this procedure.


2. Place the bike on the centerstand and remove both seats.


3. On the right side, remove the plastic fuel line cover.


4. Also on the right side, locate the two smaller diameter vent lines and diconnect from the the plastic coupler. Leave the lower lines attached to the frame


5. Next (still on the right), disconnect the multi-pin electrical connector.


6. Clamp the upper fuel line closed, then disconnect. If you haven't already drained the tank, this is the time to do so. At this time there will be about a gallon of fuel in the tank you cannot easily drain. When finished be sure to clamp the line securely.


7. Disconnect the lower fuel line, Be prepaired for a small amount of fuel to drain.


8. Remove the tank mounting bolt on the rear of the tank.


9. Carefully remove the tank.


10. Position the tank so there is access to the fuel pump assembly. THERE WILL BE A SMALL AMOUNT OF GAS REMAINING INSIDE.


11. Remove the six screws, noting the origional position of the pump. When reinstalling the pump you will rotate the pump one bolt hole counterclockwise from the origional position. This will allow the pump inlet to dip lower into the tank.


12. Pull fuel pump assembly out of the tank about 2 inches.


13. Find the two small vent hoses that are held in with plastic clamps. Using needlenose pliers carefully remove the lines WITH THE CLAMPS IN PLACE. This is a matter of using leverage to push the lines and clamps off.


14. Remove the fuel pump assembly fron the tank. Be careful to not bend the fuel level sending unit


15. Using the size 25 torx bit, remove the gas cap assembly.


16. Place new o-ring in the slot of the filler cap of the new tank.


17. Reinstall the gold inner assembly, with vent hoses oriented to the right side of the tank.


18. Place locking cap on and reattach the torx connectors.


19. Reroute the vent hoses through the fuel pump assembly hole


20. Put o-ring in groove on fuel pump assembly


21. Keeping the vent hoses out, carefully re-fit the fuel pump into the new tank.


22. Grease the end of the metal nipple attachment for the vent hoses and slide the vent hoses complete with clamps back on.


23. Re-install the fuel pump, rotated one bolt hole counterclockwise from the origional position in the stock tank using supplied bolts and washers.


24. Snip the zip tie on the multi-pin connector on the exterior of the fuel pump assembly to allow for more working room.


25. Attach the brass fuel fittings to the bottom of the tank. Tighten just until the o-ring begins to compress.


26. Attach 2 provided fuel lines with quick disconnect mounts to the brass fittings,


27. Crimp clamps onto brass fittings. Route the lines across the front of the bike and connect BELOW THE TELELEVER ASSEMBLY.


28. Remove upper fuel line (closest to the gas cap) and replace with supplies hose and clamp.


29. Attach vent hose with xxxxx printed on one side to the forward vent (this is the water drain).


30. Attach fuel tank vent line to the rear vent attachment. Attach brass fuel fittings to the bottom of the tank, tightening just until the o-ring begind to compress.


31. Some modification to the rubber cushion between the tank and the "proboscus" wil be required. Trim rubber from the top 1 inch to allow tank fitting.


32. Transfer rubber mounting bushings from stock tank to the new one.


33. Carefully mount the tank on bike.


34. Before you set the tank all the way on you must reconnect the multi-plug wire.


35. Attach new fuel hose and clamp to top fuel line and installl clamp.


36. Add 1/2 gallon of fuel and check bottom crossover fittings for leaks.


37. Bolt on tank.


38. Reattach vent hoses and zip tie to frame.


39. Reinstall seat.

Prepping and painting of new 41 L nylon (polyamide) tank.
1. Plastic adhesion promoter PPG product # DPX 801
2. DP sealer various #'s 90,40,48
3. Wetsand to smooth imperfections
4. DP sealer second coat
5. Base coat/ Clear coat system or single depending on color and application.

Intructions courtesy of Touratech-USA

Made by Elkamet. Touratech

Supplier: Bracken Motorcycles (London)
 
 
 
 
Note: Don't lose this tiny e-clip. It's for the float lever
 
Cross-tube, with QD disconnect and fittings. Also notice the new float rod and the tiny e-clip (as above) in the bag.