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These are a few pictures of the fuel cell I installed on my 2002 BMW K1200RS. After my last trip I decided that having to stop every 120 miles or so for fuel was a PITA so the following is my cure. I don't know weather this arrangement is IBA approved or not. My main objective was a cost effective setup that would get me 250 miles without having to stop and refuel.

Note, Please read the disclaimer at the bottom of the page!

I have decided against installing the cell in the Givi as I am afraid of fumes building up and causing a bomb like danger. I suppose one could vent the case but I have chosen not to. I have also discovered the ball valve is not needed as the diaphragm type fuel pump will not permit the backward flow of fuel from the return line. (05-10-03)

 

The first thing I had to do was get her clothes off.

 

Then I had to remove the charcoal canister. I installed the fuel pump and relay where the canister was. The switch is also installed on this panel. I used a boot off of an old coil wire along with some RTV to seal the back of the switch.

 

This is a shot of the panel reinstalled. I installed a filter in the vent hose from the main fuel tank that was disconnected from the evap canister. I wanted to keep critters out. I also installed a filter just before the pump. The pump is a universal pump purchased from an auto parts store along with the fuel hose. Switch and assorted electrical connectors are from Radio Shack. The fittings were purchased at a local hardware store.

  The total cost excluding the Givi was $190.00 this includes the cell purchased here .  The E46 is around $200.00 and the mounting kit is around $100.00.  List of components is :

1  - fuel cell

1 -  universal fuel pump

1  - relay

1 -  switch

3 -  1/4" npt to 5/15" barb fitting

1 - 1/4" ball valve

1 - 5/16" tee

1 - fuel filter (5/16" at both ends)

10 hose clamps

6' - 5/16" fuel hose

1 - quick disconnect if your bike isn't equipped with one. Available here for $23.00 each. But I used the one from the return line on the bike and replaced it with a brass tee.

miscellaneous electrical connectors and bolts to secure the cell

 

I removed the quick disconnect from the return line and installed a tee so I could connect the hose from the auxiliary cell.

 

This is the lighted rocker switch installed just below the power outlet on the left side.

 

I installed a 1/4 inch ball valve to be sure the main fuel pump could not force fuel into the auxiliary cell. I can easily reach both the switch and valve while riding.

 

I drilled a 7/8 inch hole and installed a PCV grommet to protect the hose and provide a weather seal. It's hard to see from this shot but it's there. I also reinstalled the quick disconnect that was removed earlier so the Givi can be removed easily.

 

Just to give you an idea of the amount of room left, or not left for storage

This is the 3.5 gallon cell installed in the Givi E46. Brackets are bolted to the bottom and the top closes fine. I am going to install a drain and a vent tube on top as a precaution. I can still put a few tools or other items in the case. I also have the luggage rack on top that can be used. Along with the side cases and tail pack this should be plenty of room for my solo travels. I discovered on my trip out west that too much room means I bring too much unnecessary stuff. 

 

This is a view of the cell installed directly on the Givi rack. Below is rear view of the same . I've decided to run the cell installed like this and remove it if I need the extra space of the Givi top case.

The weather has finally cleared up here and I was able to test the tank on the road. I got 240 miles before the low fuel light came on. I'm loving it, now I'll really be able to get my $$ worth out of the ugly Day Long Saddle J There is no foam in the cell but slosh was not a problem I have a piece of foam 7"x4"x16" that I am considering stuffing in it. But then I got to thinking about all the Harleys I rode through the years and they had no foam. Hell my old sporty only had one hole in the tank and it was for the fuel supply to the carb. It didn't even have a vent. The cap is vented so if enough pressure it built up it won't explode!

   The simpler things are the better I like them. I deal with technical electrical and mechanical crap all day at work so this is a simple design and installation for fuel cell on a K12RS. If your a techie or an engineer type I doubt you will find it acceptable but hey I spent less than $200.00 and can go a long way without having to stop for fuel so I'm a happy camper. Ride safe and enjoy life, none of us a promised a tomorrow.

 

Feel free to contact me if you have any questions and I'll do my  best to answer them.  Thanks for looking.

Disclaimer: This system is not approved by anyone. I do not recommend anyone duplicating it. If you choose to do so you do it at your own risk. I'm sure that removing the evaporative emissions canister is in violation of EPA regulations and for this reason I do not plan to operate this vehicle on public highways! J

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