Auxiliary fuel tank fitted - JAZ cell

Alan

New Member
2011 Site Supporter
Joined
Oct 10, 2011
Messages
90
Ox, in your original post with pictures, the picture right below " Disconnect the electrical plugs then methodically remove the hex screws from around the retaining ring." shows a bracket that is bolted to the fuel pump retainer. It has black vinyl on it.

None of your pictures show any hoses or wires running through this. Unfortunately, I didn't take any pictures when I took the bike apart and can't figure out the purpose of this bracket.
 

stevepsd

New Member
Founding Member
2011 Site Supporter
2012 Site Supporter
Joined
Oct 3, 2010
Messages
1,500
Location
Idaho & OR
Alan said:
Ox, in your original post with pictures, the picture right below " Disconnect the electrical plugs then methodically remove the hex screws from around the retaining ring." shows a bracket that is bolted to the fuel pump retainer. It has black vinyl on it.

None of your pictures show any hoses or wires running through this. Unfortunately, I didn't take any pictures when I took the bike apart and can't figure out the purpose of this bracket.
Nothing runs thru this bracket. It appears that the main purpose of this bracket is to allow the tank to rest on this metal bit, instead of the delicate plastic fuel-pump bits when you have the tank removed from the bike.
 

Alan

New Member
2011 Site Supporter
Joined
Oct 10, 2011
Messages
90
HeeeeeHeeeee. Maybe that's why I couldn't figure out how to get anything to go through it. Thanks, Steve.
 

VikingOlly

New Member
Joined
Jul 7, 2019
Messages
5
Location
Canberra, Australia
I finally got around to transplanting the JAZ tank from my Blackbird to the Tenere.



Firstly, remove the bodywork from the left and right sides to access the tank mounts.
2 screws and the tank is free to swing upward - I supported it with a strap to allow quick adjustment of the angle.







Disconnect the electrical plugs then methodically remove the hex screws from around the retaining ring.






Even with the tank syphoned "dry" fuel will flow once the pump is freed - catch it.






Removing the pump is difficult as the sender unit catches on the tank opening. I disconnected the sender while it was still in the tank.






Once out it can be clicked back together. Refitting it didn't catch on the tank opening.






I found an appropriate flat spot and used a "unibit" to make the hole.






The bulkhead and 90 deg elbow with barb was selected, fuel safe thread sealer used and tightened with a stubby-handled socket through the tank opening.












I fabbed a simple 3mm aluminium plate as a flat platform in place of the pillion seat and rear rack, drilled holes for the existing bolts and mounted up the tank on a simple frame. I can't weld - its all bolted.






On the left side of the JAZ tank there is a bulkhead, 90 degree ball valve and an inline filter.






The right side has an elbow, then a BMW "dry break" quick disconnect, then hose to the bulkhead affixed to the main tank.







It gives an extra 5 US gal or 19 litres, so just under the IBR limit of 11.5 gal and good for well over 600km range. ::008::

Thanks OX, I can now see and understand how you did it. Far easier than it is on the GS Adventure where its a real pain getting a flat-spot and a spanner any where near it.
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
You've already got 7.9 gallons Olaf! The poor bike will break before you go full range if you carry 11.5 gallons. ;) Lets not see you having to put any chain in your aux tank in 2021.
 

VikingOlly

New Member
Joined
Jul 7, 2019
Messages
5
Location
Canberra, Australia
You've already got 7.9 gallons Olaf! The poor bike will break before you go full range if you carry 11.5 gallons. ;) Lets not see you having to put any chain in your aux tank in 2021.
I Do on my BMW GSA have 30 Gallons. On a Tenere there is 22 litres from memory, which is considerably less at 4.8 gallons vs 11.5 allowed in the IBR
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
30 gallons? 30 liters would be right for the GSA. The Super Ten is 23 liters stock. That's 6.1 gallons. I have 31 liters on my Super Ten with a frankentank. With a 350 mile range, even if I was doing the IBR again I don't think I'd bother with the aux fuel to pick up the extra ~12 liters. I used to run an aux tank on the Super Ten with a total of 10.9 gallons, (41 liters). No longer, just the enlarged main tank.

Just saying I wouldn't bother trying to add an aux cell to the GSA. As you said, it's difficult to find a spot for the fitting and to access the inside of the tank to secure the bulkhead fitting. You've already got a decent range.

I can't recall if the GSA uses a plastic tank. I'd not choose to drill holes in that, though people certainly do. I installed the aux fuel in Cletha's old F650GS plastic tank by running the line in at the charcoal canister/vent line after deleting the charcoal canister system. I did fabricate a new plate there at the top of the tank where the original vent lines when in. With the aux tank mounted in pillion position this worked well.

We have no plans to install aux fuel in her GSA.
 

VikingOlly

New Member
Joined
Jul 7, 2019
Messages
5
Location
Canberra, Australia
30 gallons? 30 liters would be right for the GSA. The Super Ten is 23 liters stock. That's 6.1 gallons. I have 31 liters on my Super Ten with a frankentank. With a 350 mile range, even if I was doing the IBR again I don't think I'd bother with the aux fuel to pick up the extra ~12 liters. I used to run an aux tank on the Super Ten with a total of 10.9 gallons, (41 liters). No longer, just the enlarged main tank.

Just saying I wouldn't bother trying to add an aux cell to the GSA. As you said, it's difficult to find a spot for the fitting and to access the inside of the tank to secure the bulkhead fitting. You've already got a decent range.

I can't recall if the GSA uses a plastic tank. I'd not choose to drill holes in that, though people certainly do. I installed the aux fuel in Cletha's old F650GS plastic tank by running the line in at the charcoal canister/vent line after deleting the charcoal canister system. I did fabricate a new plate there at the top of the tank where the original vent lines when in. With the aux tank mounted in pillion position this worked well.

We have no plans to install aux fuel in her GSA.
APologies, yes 30 litres, down from that on the R1150GS! The GSA has a metal tank.
More importantly, can you give me some information on the "Frankentank"? Is this a concept or an actual brand - I cannot find it as such on the web. Where can I find details or photos of the enlarged tank for the Super Tenere please?
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
More importantly, can you give me some information on the "Frankentank"? Is this a concept or an actual brand - I cannot find it as such on the web. Where can I find details or photos of the enlarged tank for the Super Tenere please?
"Frankentank" or "Supertank" are names given to expanded OEM tanks that have been sectioned and had metal added to increase capacity. Not a brand, more general terms describing these.

Here is a link for another Super Tenere expanded tank. LINK

Some pictures of my tank in this thread: LINK LINK 2

Since the forum changed format, I can't find my old thread from 2017 that outlined and had pictures of my 8.2 gallon supertank/frankentank.

There have been several made now. Some DIY, I had mine done by a local to me welder in St Geroge, UT when I was living there, Jaxon Fife of Ride On ADV makes them too.

Basic process is to find a donor tank, find a welder that will do it for a price you're happy with, get it done, get it painted or coated with bedliner, (I used LineX premium, which is gas proof), and either swap over your cap and mounting hardware from your other tank or source it from the donor tank or buy replacement parts, new or used.

I did not coat the inside of my expanded tank. I did check if for leaks before I had it coated on the outside. Costs - donor tank - $200, Welding - $600, Cleaning - $40, LineX coating - $250, Hardware - $25 or a total of around $1100, as memory serves. Aux tanks are cheaper!

I chose to do this for various reasons, one being that we were considering spending a year on the road exploring and I wanted camping space on the back rather than a fuel cell. The other being that I wasn't doing rally riding so just having the same range as Cletha's GSA made things simplier. If I needed gas, she needed gas, no need for one of us to have to put a little fuel in the aux tank to match the other's range. (She used to do that with the F650GS, then I was doing that on the S10 when she got the GSA.)

If you want some more pictures of things in progress, ping me off list or PM with your email and I'll see what I can find. You just have to section the tank in two places to raise it up enough for the ~8 gal capacity. You can't easily get more than that w/o interfering with the handlebar swing. I have 2" ROX risers as well. I don't think I could use my tank w/o risers of some kind.
 

craigincali

Active Member
Joined
May 21, 2012
Messages
148
Location
A Town called Hell !!
OX-34 So are you relying on gravity to get ihe fuel to the Stock tank?
The black house on the passenger side is a vent hose?
What's the wire to/ from? I am assuming a ground?
I want to do this asap but in not exactly sure what I'm doing haha
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
I'm sure OX will respond too.

The black hose is vent/overflow and dumps anything safely out the back past the tire. The wire is indeed a ground wire, required for plastic tanks, not required for metal tanks mounted to metal of the bike, but never a bad idea either. Prevents static build up at the nozzle when re-fueling.

The biggest issue in rolling your own aux tank is figuring out a bracket/mounting set up for what ever general purpose tank you buy, (JAZ, Tour-Tank, RCI, Moon, etc.). Instructions for drilling a bukhead fitting in a tank are HERE. I put mine on the rear left bottom of the tank, others have done it on the rear right bottom area. You want the shortest run of fuel line to your aux tank. Trimming some plastic to keep a strait run is a good idea. Up and over loops create air pockets in the line and can prevent fuel transfer in gravity feed systems. There are many reasons to use gravity feed. Done well, there is less to worry about and less to fab and mount.

Don't forget that you may need to raise the tank with the aux cell installed, so you'll want a dry break under the seat area to allow this and the ability of the hose to move enough to raise the tank w/o removing the hose from the tank fitting itself.
 

craigincali

Active Member
Joined
May 21, 2012
Messages
148
Location
A Town called Hell !!
What size fuel lines? You came off the tank with a 90, into a ball valve, then a dry break under the seat to a bulk head under the stock tank?
-8 fitting?

I'm planning on using this
Screenshot_20191027-180618_Chrome.jpg
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
I prefer to run 5/16 Marine grade lines. You can get these from any place that sells outboard motor stuff. It's two layer and more resistant to crimping and damage. Still small enough to route ok through the places you need to route it. You'll want the valve where you can reach it with your left hand, but you have the basic idea. Install a clear plastic disposable fuel filter in the line off the Aux tank between the tank and the valve. Buy two when you find the size you like. One is your spare to carry with you. If you think you got some bad gas, you can check the filter and see if it's got crud in it. That might save you a lot of headaches. So.. 90º fitting off the Aux tank to a 5/16 hose barb. Fuel line to filter, fuel line from filter to where ever you are going to mount the ball valve. Do NOT use plastic valves or dry break fittings. That's just failure waiting to happen. Then fuel line from the ball valve to the female dry break fitting. I like Chrysler Force style marine ones. You can get them at Napa stores and many marine supply stores. One side has a hose barb, the other needs a fitting to go from NPT to hose barb. Reasonably cheap. Another proven type is Jiffy-tite Female / Male.

Put the male end of the dry break on the Main tank side so you can more easily pull the line thru when you need to raise the main tank for service work.

With that JAZ tank you will need to leave room for the drop sump when you create the mounting plate, but it should drain all the fuel well. I'm not a fan of foam, it breaks down over time and will clog the fuel system. Having an inline filter really saves your bacon then.
 
B

ballisticexchris

Guest
As Eric says get a filter!! I also used the Jazz tank for my Iron Butt. The foam clogged up the filter just when I finished the ride.

IMG_3031.JPG
 

OX-34

Active Member
Joined
Aug 20, 2011
Messages
378
Thanks for those replies Eric, I've been absent for a while. Craig if you follow Eric's links and where to buy bits you will be fine.

As for the aux tank sump, if you look at my JAZ install, the tank is sitting on two sections of 50mm/2 inch alloy square tube. I have used the steel loops/straps that came with the tank and bolted down onto these 50mm tubes. It is rigid and lifts the tank up off the sump. From there you can just bolt the 50mm tubes down onto whatever you use as your base rack.

I have used this JAZ tank system on a bunch of bikes...









 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
I have used this JAZ tank system on a bunch of bikes...

Got to love a Postie bike with an Aux tank. What was the range on that? I'm hoping to buy a couple of the new CT-125 Postie bikes when/if Honda brings them to the US. Already put an order in at my local dealer.
 

EricV

Riding, farkling, riding...
2011 Site Supporter
2012 Site Supporter
2013 Site Supporter
2014 Site Supporter
Joined
May 22, 2011
Messages
8,227
Location
Tupelo, MS
Does the tank come with the 2 straps or do I have to buy the mounting kit.?
Typically tanks do not come with mounting straps. Inquire with the seller before you purchase the tank.
 
Top