I've been poking around the forum for a few years after BMG loaned us a 650 for the Baja 500. I bought a 2005 fe650 a few weeks ago and purchased the .75 (3 liter) gallon tank. I installed one the '04 race bike but didn't like the ignition module mounting and it vented fuel the overflow continuously. With these things in mind, I got some advise and ideas from BOSS and PowerCell, so here is what I did.
1. I cut the tab for the ignition and welded it to the mount for the fuse block above the battery. It's double-rubber mounted and fits perfect. I got the idea from Rick at BOSS. He told me that he zipty'd one this way and it was holding up just fine.
Ignition Mount
Ignition Mounted #1
Ignition Module Clearance
2. I installed a 90 degree angle fitting to the tank and connected the vent hose thus creating a closed system. This part is from IMS (800-237-9906), 90 degree vent fitting (part #218395). This original idea from PowerCell
Tank Vent
Tank Vent Fitting
3. The balance of the installation is a tug 'o' war to get the tank lined up and bolted in. Mine was missing machine screws and clamps, which are available at the local hardware store.
Inside Fender Picture
You can mount the ignition module on the headset but it tends to get in the way of silly thinks like lights and wiring. I've also seen venting done through the filler cap, this isn't necessary if you close the venting loop to the main tank.
Will it work, you ask? The answer is like a champ. I took the 650 down to Mexico for two days and rode 430 miles and the whole system worked perfectly. We rode the street, dirt roads, single track, rocks, whoops and even on the beach for 30 miles. As we say in CA, "Dude, this thing is money."
1. I cut the tab for the ignition and welded it to the mount for the fuse block above the battery. It's double-rubber mounted and fits perfect. I got the idea from Rick at BOSS. He told me that he zipty'd one this way and it was holding up just fine.
Ignition Mount
Ignition Mounted #1
Ignition Module Clearance
2. I installed a 90 degree angle fitting to the tank and connected the vent hose thus creating a closed system. This part is from IMS (800-237-9906), 90 degree vent fitting (part #218395). This original idea from PowerCell
Tank Vent
Tank Vent Fitting
3. The balance of the installation is a tug 'o' war to get the tank lined up and bolted in. Mine was missing machine screws and clamps, which are available at the local hardware store.
Inside Fender Picture
You can mount the ignition module on the headset but it tends to get in the way of silly thinks like lights and wiring. I've also seen venting done through the filler cap, this isn't necessary if you close the venting loop to the main tank.
Will it work, you ask? The answer is like a champ. I took the 650 down to Mexico for two days and rode 430 miles and the whole system worked perfectly. We rode the street, dirt roads, single track, rocks, whoops and even on the beach for 30 miles. As we say in CA, "Dude, this thing is money."
