Since I needed to drain the fuel from the tank to do the O-ring recall/check (mine was ok, btw) I decided to check the actual fuel capacity of my tank. I rode around until the low fuel segment started flashing and got home in 2.5 miles from it coming on. I siphoned the remaining fuel out of the tank and measured 180 oz of fuel remaining. based upon the design of the fuel tank/pump it looks that all but about 4oz-6oz is useable. So to be conservative, say 1.25 US Gallons (160 oz) of reserve capacity.
I then measured how much fuel it took to fully fill the tank. Mine was 6.125 US gallons (784 oz). Pretty darn close the 6.08 gallon capacity listed in the owners manual.
I also took the opportunity to take a look at the fuel pump. The pump is modular, and real easy to disassemble. There was some debris in the fuel pickup filter (as shown in the pics).
Since I always hated the filler neck restrictor (it was a pain to fill - kept spitting fuel back at me, fuel nozzle at a awkward angle, etc) I decided to cut it out. Real simple mod using a air die grinder with a abrasive cutoff wheel (after letting the tank air out for a couple of days - don't want any boom!). Since the restrictor is just over 1 inch in height (depth), it does free up some tank capacity. My tank now holds 6.35 US gallons (813 oz) almost another quart. Plus it is much easier to fill and no splash-back!
Washed the tank out real good and the fuel pump opening makes it pretty easy to reach inside and wipe down the tank. It helps if you have long, skinny arms also. You definitely don't want to get you arm stuck in there though....it really diminishes your tank capacity if you have to hack it off!
29 DEC 2011 UPDATE:
After running the tank dry, there was 9 ounces of fuel remaining.
To itemize for my stock (unmodified) tank:
TOTAL USEABLE CAPACITY (unmodified tank): 6.05 US Gallons
TOTAL MAIN TANK CAPACITY (prior to reserve): 4.72 US Gallons
RESERVE CAPACITY (useable): 1.33 US Gallons
After modifying the tank by cutting out the restrictor:
TOTAL USEABLE CAPACITY (modified tank): 6.28 US Gallons
TOTAL MAIN TANK CAPACITY (modified tank - prior to reserve): 4.95 US Gallons
RESERVE CAPACITY (useable): 1.33 US Gallons
I then measured how much fuel it took to fully fill the tank. Mine was 6.125 US gallons (784 oz). Pretty darn close the 6.08 gallon capacity listed in the owners manual.
I also took the opportunity to take a look at the fuel pump. The pump is modular, and real easy to disassemble. There was some debris in the fuel pickup filter (as shown in the pics).
Since I always hated the filler neck restrictor (it was a pain to fill - kept spitting fuel back at me, fuel nozzle at a awkward angle, etc) I decided to cut it out. Real simple mod using a air die grinder with a abrasive cutoff wheel (after letting the tank air out for a couple of days - don't want any boom!). Since the restrictor is just over 1 inch in height (depth), it does free up some tank capacity. My tank now holds 6.35 US gallons (813 oz) almost another quart. Plus it is much easier to fill and no splash-back!
Washed the tank out real good and the fuel pump opening makes it pretty easy to reach inside and wipe down the tank. It helps if you have long, skinny arms also. You definitely don't want to get you arm stuck in there though....it really diminishes your tank capacity if you have to hack it off!
29 DEC 2011 UPDATE:
After running the tank dry, there was 9 ounces of fuel remaining.
To itemize for my stock (unmodified) tank:
TOTAL USEABLE CAPACITY (unmodified tank): 6.05 US Gallons
TOTAL MAIN TANK CAPACITY (prior to reserve): 4.72 US Gallons
RESERVE CAPACITY (useable): 1.33 US Gallons
After modifying the tank by cutting out the restrictor:
TOTAL USEABLE CAPACITY (modified tank): 6.28 US Gallons
TOTAL MAIN TANK CAPACITY (modified tank - prior to reserve): 4.95 US Gallons
RESERVE CAPACITY (useable): 1.33 US Gallons
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