Thursday, December 1, 2011
Auxillary Fuel Tank BMW G650Xchallenge Installation Instructions
Installation
1.) Remove seat. Remove tail section
screws as shown in the photo, pull slightly forward to release the tab and
remove the tail section cover. Remove the front airbox cover/side cover. Pull out the battery and disconnect it.
2.) Disassemble and remove the exhaust muffler.
3.) Disconnect the rear blinker and taillight plugs at the rear of the tank.
4.) Remove the two rear tank attachment screws. DO NOT DROP the spacers. They will fall out when the tank moves off its mounts.
5.) Disconnect the hoses from the emissions canister (US Version). Clip zip-ties holding wires and hoses to the subframe. Remove the upper and lower rear subframe screws on both sides. Remove the rear subframe slowly ensuring there is nothing still attached.
6.) Remove the four airbox screws.
7.) Pull fuse box up and put aside (A) Use a screwdriver to depress the tab locking it to the airbox.
8.) Unplug the sensor on the underside of the airbox, remove the 2 rubber mounted electrical units, and the crankcase vent hose. Lift up the airbox and put it aside.
9.) Remove front tank attachment (B) DO NOT DROP the spacer. It will fall out when the tank moves off its mount.
10.) Remove the two screws and remove the fuel fitting from the fuel tank; pay attention to O-rings! Disconnect the fuel pump electrical connector.
11.) Pull the tank away from the frame.
12.) Empty the fuel tank.
13.) Turn the large fuel pump retaining ring nut (6A). open with a suitable tool.
14.) Cut out the drill template.
NOTE! Due to brake line banjo fittings close to the bottom of orig. tank, the ABS models has very little or no room for TWO fuel fittings installed on the bottom of the tank. Re: photos 8-11. We generally suggest only using one fuel line/fitting with ABS and building a fuel line T-fitting for the two fuel lines coming from both tank lobes. Fuel line T-fitting is not part of this tank kit. Attention! Ensure the scale is correct by comparing template to the actual fuel fitting plate before drilling!! BE VERY CAREFUL – YOU’RE DRILLING HOLES IN YOUR GAS TANK SO THEY MUST BE CORRECT THE FIRST TIME! Tape template in place on the lower front part of the fuel tank and punch markings for the four smaller outer holes.
download: http://www.cycoactive.com/media/VXqoCZ/09-049-0130-1.pdf
