Hi, I am about to purchase the touratech tank expension kit for the bmw 650gs. Anyone out there can tell me how hard it is to fit? can I do it myself or should I get a profesional? any chance i can realy mess up the bike? also are they any alternatives on the market?

http://www.touratech-usa.com/instl/instl_100-1100.html

Not hard at all. It was the first real work I did on a motorcycle (other than change the oil, air filter, light-bulb kind of stuff).

The instructions for the add-on tanks only installation leave a bit out. They came from the full TT-39 conversion where you basically replace the rear sub-frame and a bunch of other stuff - including wiring harnesses and all. Some pictures and a few steps in the full conversion instructions are missing from the tank only piece, so get both and you should have no troubles.

My biggest problem - as a novice mechanic - was figuring out how some of the electrical connectors came apart.

Another thing to keep in mind - the conversion is for the F650 dakar prior to 2005. The 2005 model is a wee bit different - the air intake being the main change. I ordered a replacement intake snorkel and it was the type from the 2004 and earlier model which made it possible to reinstall around the bolt-on add-on tank frame (you have to trim the snorkel a bit).

Additionally, that plastic front beak has to be trimmed a little - its a different shape then prior year models and has two points that hit the add-on tanks when you turn the front wheel full.

I got a glance at the new 2006 Touratech catalog and I don't think they've changed the kit any. You might want to contact Germany and ask about this.

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quastdog
Chiang Mai, Thailand

I installed on a 2002 Dakar. Taking my time and making sure everything was right (I am by no means a mechanic!) it took me 2 days (5-6 hours each day). It is not difficult at all. The only scary bit is drilling a hole in the original tank, but TT provides good templates that make that a foolproof affair. Set aside 2 days, take your time and you'll have fun! Its a great addition to the bike, but it takes a few days riding to get comfertable with the new setup. Your legs are much more spread when riding. Not bad, just different. LOVE the 700+ km range...

We just completed an installation on my 2004 F650GS Dakar. For me, this thread was invaluable going into the project so I want to "give back" with some things I ran into. The estimate of 2 days at 5-6 hours a day is accurate and it is not dificult.

You will note I said "we" just completed the installation. Dave Andersen of Touratech Canada gave me a lot of advice and help when I needed it. For anyone interested I know Touratech Canada currently has one TT39 tank kit in stock.

The first item I ran into that was not noted in the instructions was to remove the BMS control unit and holder from the tank and to disconnect the the plug for the rear light/turn indicator. (I don't know what the BMS is exactly, I am reading out of a manual but) It is an electronic box located in front of the fuel pump and is mounted to the tank. You also need to remove the plug for the rear light/turn indicator from the holder and clip a couple of cable ties.

The next item of note is that the original tank for the USA version is noted in the instructions as having a charcoal canister which means drilling the fuel connection on the right side while for the Eurpoean model it is drilled on the left.

My 2004 Dakar does not have the canister. I am not sure if this is because of the model year or because it is a Canadian model vs. USA. I did have a Canadian model 2003 F650GS previously and it did have the canister. I installed the connection on the left side as recomended for the European model.

As noted previously in this thread, the air intake duct did not fit once the front tank mounts were installed. We used a heat gun to soften the plastic duct and depressed it a little where it was hitting the mount. This worked well.

Touratech states "Beginning with the 2004 model, you need to purchase the front mudguard/fender assembly and hardware from the 2003 model as well as the tank emblems from BMW." I think replacing the fender was the way to go rather than trying to trim the original to clear the tanks.

I hope some of this is helpfull to anyone undertaking this conversion. For more information I would suggest contacting Touratech Canada or Anderwerks at parts (you know whAT goes here) anderwerks Dottt com

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Bill Atchison
Red Deer, Alberta Canada
www.backroadexplorers.ca