2.2 Gallon TourTank Installation

2.2 Gallon TourTank Installation Daniii posted a thread on installation of the 3. 5 gallon auxiliary tour tank here=> LINK If you intend to use the auxiliary tank frequently, view that thread first as his installation is of a more permanent nature that the one that follows. However, if you don't have saddlebags, you may still want look at this one for mounting on the luggage rack. I only intend to use the tour tank when going on long trips, so this is a temporary installation that is a little simpler. It mounts the tank in the existing "luggage" rack and all the tubing is removed when the tank is not in use. I purchased the 2.25 gallon tourtank from Tourtank.com. I also purchased a quick release fitting. The deluxe package includes the tank, fuel line, clamps and shut-off valve. I purchased the tank with the built-in vent tube. (See last slide for tank part names)

STEP 1: Gather necessary tools

To mount the tank I used a piece of 1/2" aluminun stock that I had in the garage (1/2" is overkill; I think that 1/4" would be fine). I made a cardboard template of the rack with the tank on top. Note: make sure that the tank is placed in such a way that the bolts securing the tank brackets to the plate (mounting bolts) don't land on top of the luggage rack cross bars (left arrow).

Mark where the brackets rest on the plate so that you can drill the holes for the bracket in the correct place and cut the plate (ignore holes in picture for now).

I will attach the mounting plate and tank to the rack using hose clamps (for a more elegant installation you can cut the mounting plate wider and use u-bolts). In the mounting plate, mark the location of the rear cross bar of the luggage rack so that you can drill holes for the hose clamps in the correct position. Mark the holes for the bracket mounting bolts and for the tank outlet. Drill holes for the bolts, tank outlet, and hose clamps. I also drilled two extra holes towards the rear of the plate to use wide cable ties to additionally secure the plate to the rack in case the hose clamps fail. To drill the hose clamp slots I drilled two adjacent holes and connected them with a reamer (ignore the extra holes in the figures, they were there before I started).

Use a metal file and round off the edges of the hose clamp slots and of the rack where the hose clamps will contact. Then, glue some type of non-slip material to the bottom of the mounting plate (I used heavy duty gasket material, but anything will do) to keep the rack from slipping and to protect the luggage rack. Mount the tank to the rack and test the installation.

Remove the tank from the brackets and use the mounting plate as a template to mark the location of the four bracket mounting holes and the tank outlet in the bottom of a small gym bag (I got mine at Wallmart for $12.00). Drill or cut the holes in the bottom of the bag (and through the cardboard stiffener if your bag has one).

Cut of the wall separating the main compartment of the bag with one of the side pockets (wet pockets). Make sure tank fits through opening.

Mount the brackets inside the bag to the mounting plate (outside the bag). With the brackets open, insert the tank from the side that you cut (the neck will go through the bracket openings). When it is through the first bracket, twist it up straight and secure the bracket bolts.

Rather than use the in-line shut-off valve provided with the tank, I purchased one that goes straight into the tank here=> Cheapbiker This keeps fittings and other scratchy stuff off the bike‘s paint. I also had to get an extender as the valve would not clear the aluminum plate and luggage rack (it may clear with a 1/4" mounting plate).

Connection is simple. Extender (a) and shut-off valve (b) into the tank (use locktite), short piece of hose, quick release fitting (c) long piece of hose, in that order.

Connect the fittings and quick release first, then mount the whole assembly to the luggage rack with the cable clamps and cable ties, then attach the long hose section (with the other side of the quick release fitting) and measure length needed (see next slide).

Run the long hose from the quick release fitting along the side of the rear fender, under the seat (careful not to pinch), and into the tank's breather tube (next slide). Secure hose against edge of seat with cable ties so that it is not so visible (not done in this picture yet to show the hose run).

Connection to VROD tank

Attach a short piece of hose to the TourTank's vent tube so that it vents outside the bag.

You’re done…

Put away what’s left of your tools.

Filling up: If there is still gas in the TourTank there is no need to check the regular tank (the gas gauge should read " full" ). Just fill the TourTank. If you need to add gas to both: First shut off the Tour Tank valve, then fill the regular tank, close the gas cap, fill the TourTank, and open the valve.

Tank Parts: tour tank vent tube bracket bracket bolt mounting plate mounting bolt