When adventure riding, larger fuel tanks like the Safari tank are a great idea but when they are fitted to a motorcycle with a backbone frame and the tank wraps over the frame then quite often a large amount of the fuel can get trapped on one side of the tank. If that happens you must pull up and tip the bike on its side to get the fuel to the side with the fuel tap. Many of these tanks already have a molding in them to fit a second fuel tap so here’s a step by step guide on how to do the job.

#1 TANK OFF

Start by removing the seat and fuel tank from the bike but before you do clean a nice large work space on your bench to lay the tank to work on it. Even lay down a towel or a heap of rags so the tank doesn’t get scratched up on the bench.

#2 EMPTY IT OUT

Drain all the fuel from the tank. It is never recommended to go drilling any holes in your fuel tank while the tank is full of fuel.

#3 FIND THE SECRET SPOT

Lay the tank on the bench and locate the molding in the tank where an extra fuel tap is to be fitted. These are easiest to locate by the two predrilled mounting bolt holes already in the tank.

#4 TWO HOLES NEEDED

This particular fuel tap has two inlets. One is the main inlet and the other is for reserve so I will need to drill two holes but if you have a fuel tap with only one inlet then you will only need to drill one hole.

#5 MEASURE CAREFULLY BEFORE DRILLING

Measure out the distance between the bolt holes where you will need to drill your holes and then drill the holes so the inlet posts fit in the holes snuggly. These inlet posts are 8.5mm at their widest point so I am using an 8.5mm drill bit so the holes are a snug fit.

#6 MAKE SURE ITS CLEAN AFTERWARDS

Make sure you clean out any drillings from inside the tank. You can either pour some fuel through the tank and tip it out or blow it out with compressed air.

#7 EASY DOES IT

Bolt the new fuel tap into the tank but be sure to only tighten the screws softly as they only tighten into the plastic fuel tank and can be stripped easily.

#8 CUT AND CLAMP

Cut the existing fuel line in half up stream of any fuel filters and fit the fuel line t-piece using fuel line clamps to secure it in place.

#9 READY TO FLOW

Fit the seat and fuel tank back to the motorcycle and then connect the fuel line up from the new fuel tap to the t-piece in your fuel line. Now when both fuel taps are turned on the carb will be fed fuel from both sides of the tank and the tank will drain evenly.