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the new big tank, observations

I took the suggestion of Viking and cut my kick lever just below the bend and took out 1/2 inch then welded it back together. Great fit and I kicked it repeatedly ( damn thing starts every time too) and did not break it ...............YET :p

I also used the petcock from my old under the seat tank... screw knob type and that works well also.

The only thing I need now is a new piece of that stuff that they use for a bumper on the kicker. I would like it to be just about 1/4in longet than the one now. I think mine is a bit worn. Anybody know where to get some of that stuff?
 
Bobzilla said:
The only thing I need now is a new piece of that stuff that they use for a bumper on the kicker. I would like it to be just about 1/4in longer than the one now. I think mine is a bit worn. Anybody know where to get some of that stuff?
Click to expand...

It's basically a plastic or nylon dowel Bob. Pull your factory piece out, (I think it's a pressure fit with or without a touch of glue), and take it to a plastic supply house and buy a length of the stuff. We have a retail store here in Portland called Tap Plastics. Suppose you could always whittle one out of wood! :D

log
 
or buy it from a dealer for a buck?

they are available. they come very long and using a blade just slice little bits away till you have what you want.

regards

Taffy
 
Thinking pretty seriously about the larger tank for my trip to moab. Couple question though:

How bad does the larger tank interfere with the 05 kick-starter? Any pics with the older kick-starter? Does it just stick out just a little bit and is a little annoying and simpley needs a small piece of rubber or silicon to protect the tank? OR does it stick straight out and really in the way while riding?

Similarly, what about using existing petcocks? Is it a little awkward or somewhat impossible to use/install? Any pics?

Does the tank come with a cap or do you use the existing cap?
 
Tank comes with a cap, If your bike is NOT 06, 07 then your kick starter is fairly straight to the bend where it becomes the foot piece, and will hit the new tank and tuck in fully. Mine is 00 FE 501 I fitted the boss tank Wed. nite in Moab, it was fine for 140 mi "C" ride mostly pavement and jeep roads. Thursday nite I put my stock tank back on as Fri. and Sat. were a bit more technical, and I could not handle that kicker flopping out. The stock petcocks are workable but funky. Having two sets is much better IMO as you can switch tanks when changing air filters depending on the scheduled ride. The older kicker can be cut and 1/2" taken out (see bobzilla earlier post in this thread), or buy a new late model kicker about $130.00. It is VERY nice to have a 4 gallon tank for all day rides, and the tank is not bulky the fit is first rate. Just takes a bit of tweaking on a 2000 to 2005 bike to get the perfect fit.
Ron
 
Good info Stoveguy, thanks.

Boss suggested possibly using a heat gun on the tank to accommodate the older kicker? Anyone do this? pros / cons / suggestions?

Is there room for a fan with the larger tank? I am thinking about installing one for Moab? Is it needed?

I appologize for all the questions, I am relatively new to the berg and this site is a great resource!
Thanks
 
Heat gun on the tank ? Not to sure about that one since my tanks has had gas in it. Tank will work with the fan, not sure you will need it for Moab. Didn't hear of any one having over heating problems in March, May shouldn't be too hot. PM Bobzilla he had his kicker cut and re-welded after removing 1/2". He'll point you in the right direction.

Later
Ron
 
Stoveguy said:
Heat gun on the tank ? Not to sure about that one since my tanks has had gas in it.
Click to expand...

been through this several times ron. just take the tank of and place on the car exhaust for 10 minutes.

regards

Taffy
 
possibly to clarify for those of us who are visuallizing taffy using his tailpipe to heat up the tank , i believe he is purging the evil gasoline (petrol) fumes so's the tank won't 'splode. co2 fire extinguishers work too. but with today's car exhaust, they prolly put out a bunch of non volatile gases.
since mine hasn't had gas in it yet, i'll throw the old heat gun to it and see what happens. looks to me like you should have the left petcock in place to prevent warping since the area to be heated is pretty close.

ned
 
berger said:
You may have to install an aftermarket petcock on the one side for optimum fit. I know thats how it is with my aluminum tank. I purchased a few petcocks from Rick. I'm waiting until I recieve them untill I try to mount my tank.
Click to expand...

Where did you get that aluminum tank from?

~

Michael
 
I love you too man........! I'm getting misty, can I get a group hug here? I'm felling a lot of agression here lately. I think some boys need to go riding, but not buzzard and Brett those two are spoiled.
Ron
 
Got the larger tank from BOSS. Very pleased with it so far. Cut 1/2" out of the kicker so that it would tuck completely in out of the way. Very pleased with the "friend of a friend's" welding capabilities. You can hardly tell it was cut. See links to pics below (couldn't get insert image button to work)

The right petcock is in an ok position.

Although, the left petcock is not in the most user friendly position. I have the lever part of the petcock facing forward and pointing in slightly with the barb facing back and out slightly. It is a little tight and hard to actuate without burning ones digits on the exhaust or rad hose.

Anyone suggest where I would get a petcock with the barb 45 degrees to the line between the mounting bolts of the petcock? Or a petcock with a rotating barb that could be set at any angle?

Kicker Cut
http://i12.photobucket.com/albums/a206/ ... 1180320840

Right Petcock
http://i12.photobucket.com/albums/a206/ ... 1180320933

Left Petcock
http://i12.photobucket.com/albums/a206/ ... 1180320997
 
I LOVE THIS TANK. The new tank with the under seat tank, has almost 5 gallons (20 liters) of fuel in the bike. So far I've done a 150 mile ride and had 3 or 4 liters left in the tanks. The first day I rode with the tank, I filled everything to the top and rode single track. The bike did not feel significantly different even with all the gas on board.

Like Husabutt, I used the KTM petcocks off of a 950. They point the right direction. I also have the line coming in from the underseat tank. So to simplify the fuel lines and remove a "T" fitting, I purchased a duel inlet fuel nipple for the carberator from Taffy. It works well; I have one "T" fitting on the far side of the bike and that line plugs in to one of the nipples and the left petcock plugs directly in to the other one. Very clean and very reliable set up.
 
The new tank is working out great, as mentioned above hardly noticeable. I filled up last week for a local event that involved singletrack and I never had to think about the extra weight.
Now where do I find an underseat tank? Anybody?
 
James, you should be able to order an under seat tank from you friendly local dealer... It a Husaberg part.
 

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