Trail Tank Install Questions?

[DirtFarmer]

I stopped by my favorite True Value hardware store on the way to the office this morning to get some longer bolts to shim the radiator. I found these steel spacers that have a 1/4" ID x 3/4" long for $1.55 each that would make the install pretty clean I think. G.B.

View attachment 141067

What length bolts did you go with there?

 

[Gone Blue]

What length bolts did you go with there?

50 mm. They are a touch long but wont hurt anything. If you could find or cut them down to 45 mm they would be perfect with the 3/4" spacer.

The Trail Tank seems to fit great now with all the spacers accounted for and rerouting the gas tank vent line. The studs on the tunnel are as far rear in the tank slots as possible. Next up I am going to dump 5 gallons of gas into the tank and check for leaks. I am getting ready to pull the sub frame so I will hold off test fitting the body panels with the Trail Tank. Thanks to everyones help and input on this thread, especially herndonp! G.B.

 

[Hooray!]

Looks good. The body work does not fit as cleanly after the trail tank. Mine has some gaps and the holes were enlarged in the plastics to align w the trial tank. I strapped a yamaha tank bag on to cover it up and called it good! Nice to have 11 gallons of fuel.

 

[Gone Blue]

Looks good. The body work does not fit as cleanly after the trail tank. Mine has some gaps and the holes were enlarged in the plastics to align w the trial tank. I strapped a yamaha tank bag on to cover it up and called it good! Nice to have 11 gallons of fuel.

Thanks Hooray. I think these trail tanks swell with fuel in them? I had it installed as you see in the picture above and the tank slid into position fairly easy. At that time the tank hadn't had fuel in it for 2-3 years so it was dry. So after the install I put 5 gallons of gas in it and found that the o-ring for the fuel sender was damp. I bought the tank used and got the O-rings with it not knowing how old the tank was. So this past weekend I received new O-rings for the sender and pump from Tail tank and pulled the tank to install them after draining the 5 gallons of gas. Trying to install the tank a 2nd time was a PIA. It was super tight. I loosened the steering hoop and used a ratchet strap and still could not get the tank so the rear mounting studs were at way the back of the mounting slots. The only body panels I have installed so far is the tank cover. I am sure I will have to mess with it more once I install the rest of the body panels. G.B.

 

[Hooray!]

My sled came with it installed but the center plastic on the tank below the fill is trimmed (a little rough looking), body plastic / tank seams are not up to Yamaha standards and the body work bolt holes in the plastics are elongated to reach the nuts built into the new tank. I have read here on a few threads about using ratchet straps and cum alongs to pull the tank into position so seems like tight is the norm, whether from expansion or heat not sure. All said, still great to have another four gallons in basically the same real estate. I carry a 1.5 gal tank on my rack for those longer rides between fills but happy w trail tank range all by itself. I will take some pics of mine next time out to trailer. I covered it all with a Yamaha tank bag so looks great!

 

[DirtFarmer]

Went with the 3/4” spacer way with 45mm long bolts. Thanks for the idea!