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Photo by Marc Gibaud, Clouds on Tres Cerros and Mount Fitzroy, Argentinian Patagonia

25 years of HU Events


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Photo by Marc Gibaud,
Clouds on Tres Cerros and
Mount Fitzroy, Argentinian Patagonia



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Old 29 Oct 2009
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Posts: 124
Acerbis offers a 6.6 gallon fuel tank for '92 and older 1992-1995 DRs. I wanted more capacity than the IMS 5 gallon model, and couldn't see spending $550 for the Aqualine 8 gallon model.

First, the physical differences between the stock tank and the Acerbis model:





We needed a few modifications to make it fit my 2008 model.

The turn signals are in the way of the tank well before full-lock of the handlebars, so I switched the mounting brackets to opposite sides, and then reversed them. This moved the lights up and forward a bit.



Spacers had to me made for the support bolt that runs across the frame tube. It helps to have a friend with a lathe who isn't afraid to use it.




 The spacers replaced a pile of washers and other kludgy bits.


Oil cooler and crash guard: The oil cooler has to move forward a few inches. The mounting tab was easily bent by hand. The cooler guard will take more work.

Oil cooler moved forward slightly; also cut out a section of the oil cooler guard.


Fortunately, 1/2" mild steel tubing fits perfectly inside the tubing used for the stock guard. Using a tubing cutter and a bender, I pieced together a new bracket that not only fits around the tank, but provides a little more coverage than the stocker.
Mock-up:


Another angle:


Brazed and painted (sadly, my skills are lacking in both areas):


The angle of the tank doesn't quite match the angle of the seat, so I cut off the forward section of the pan:


...and the rear flange of the Acerbis tank is quite a bit thicker than the stocker -- so some tough love with a Dremel tool and a heat gun brings it into shape:

(NOTE: Yes, that is a hole in the center of the rear flange of the tank [above]. We had a discussion about whether that flange was solid or hollow, because if solid it would open up more mounting possibilities. Turns out -- it's hollow. The hole was a test and easily patched.)

And now the seat foam gets some attention. After this pic was taken I leveled off the front of the foam and cleaned up the sides up front. An angle grinder used LIGHTLY makes a great foam sculpting tool.


The Acerbis tank has two petcocks, and comes with a length of fuel hose and a cheesy plastic tee -- I replaced it with a barbed brass tee.

Result





Cheers,
Sean
Last edited by SeanF; 17 Mar 2010 at 00:44.
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Old 29 Oct 2009
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Location: South Island, New Zealand
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Nice, vvveeerrryyy nice.

Cheers bloke,

Nigel in NZ
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