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