A Different Solution to the Lack of Fuel Capacity Problem

[twolane]

So rather than going the aftermarket over sized fuel tank route ( I don't care for the look, or the extra unnecessary weight around town or on the local trails), I opted to try and make a PegPacker work. Per David's advice I ordered the BMW kit.

Following is a quick install report with a few pics. I'm really digging this setup, as it's flexible, multipurpose, and can be removed quick if need be!

First off you'll be removing the pin that holds the passenger peg on...

This clip is important! Don't lose it! It will want to go flying off, but with a little patience, it will slide off easy.

I didn't get a pic of it, but there is a spring and ball bearing on the underside of the peg that allows it to click into place. Careful again removing that peg! I lost my ball bearing. Stinks.

The new bracket goes together something like this.. you can see where the pin will go back through

Sizing up the notch on the rear block of the new mounting bracket

And there it is installed. I opted for the taller mounting option, as I'm sure most people will. More clearance for the legs, and doesn't interfere with anything up high...

Now you'll install the L shaped bracket that will hold the base for the tank.

Don't forget the Loctite!

The next part is kind of tricky.. you have to line up where you want the base to sit, and mark it for holes. I went for a farther back mount (again to leave plenty of clearence for legs and feet).
I also tried to keep the tank spaced out a bit from the heat shield as well.
Here is the base marked, then drilled for the bolts.

And now the base is bolted to the bracket! Pegpacker says in their instruction book you may have to trim one of the washers depending on placement, but rather than all that, I used a slightly smaller washer on the bottom of the one problem bolt.

Now you're done!

For about a hundred bucks you now have an extra gallon of fuel when you need it, and when you don't you can use the base for a camera mount, or remove two bolts, and the entire setup comes right off!

I have no affiliation with the people at pegpacker, I just wanted to share the good news there is a pretty affordable option for extra fuel on a husky that isn't on their site.

 

[RDTCU]

Nice, how "jiggly" is it offroad? Personally I think they should hire a welder and fire the riveter.
I wonder if they could come up with a mount to put the can down and back more, kinda tucked under the muffler but clearing the swingarm. I guess a single exhaust would make it easier...
Only other option I've seen is a Rotopack mount installed on a tail rack.

Let us know how it holds up

ETA:

 

[Motosportz]

Go to single exhaust and re-purpose the unused muffler into a fuel cell. will look stock and hold a gallon. People will crap themselves when you remove your "muffler" and dump gas from it.

 

[RDTCU]

Go to single exhaust and re-purpose the unused muffler into a fuel cell. will look stock and hold a gallon. People will crap themselves when you remove your "muffler" and dump gas from it.

Haha, i like the way you think

 

[CJBROWN]

Nice looking setup. Just don't crash on it.

 

[ContraHusky]

Where does the wiener dog ride?

 

[BrandonR]

Go to single exhaust and re-purpose the unused muffler into a fuel cell. will look stock and hold a gallon. People will crap themselves when you remove your "muffler" and dump gas from it.

I think the muffler sits high enough to gravity drain into the main tank if they were plumbed together. Install a T into the balancing line between the two sides of the main tank connected to the low point on the muffler then connect another from the high point to the extra vent port on the tank. It would fill slow but drain plenty fast enough.

I think it would be cool to have an under-seat/rear-fender tank option for tall riders, raise the seat an inch or so and add a gallon+.

 

[ghte]

Love the redundant exhaust concept

 

[twolane]

Nice looking setup. Just don't crash on it.

That's the thing that worries me. The setup is made for a pretty particular ride. Nothing to crazy offroad (some tight little single track? I think not!)

Where does the wiener dog ride?

He doesn't. He was being punished so the wife sent him outside with me. Little dude is 13 and getting pretty fragile at this point

Go to single exhaust and re-purpose the unused muffler into a fuel cell. will look stock and hold a gallon. People will crap themselves when you remove your "muffler" and dump gas from it.

I think the muffler sits high enough to gravity drain into the main tank if they were plumbed together. Install a T into the balancing line between the two sides of the main tank connected to the low point on the muffler then connect another from the high point to the extra vent port on the tank. It would fill slow but drain plenty fast enough.
I think it would be cool to have an under-seat/rear-fender tank option for tall riders, raise the seat an inch or so and add a gallon+.

Wasn't George from Uptite working on something like that a while back? Something with a pump to move the fuel from the aux tank in the rear up to the main tank? My concern would be a second mounting point. You could use the factory tab for the muffler, but wouldn't you need a second point to keep the muffler from moving around?

 

[RDTCU]

Wasn't George from Uptite working on something like that a while back? Something with a pump to move the fuel from the aux tank in the rear up to the main tank? My concern would be a second mounting point. You could use the factory tab for the muffler, but wouldn't you need a second point to keep the muffler from moving around?

A sheetmetal front mount would be fairly simple, have the inlet neck of the muffler/tank clamp to it with a band clamp, or just weld a tab onto the stainless portion.

 

[Fast1]

But how much would that spare "muffler" gas tank weigh without fuel?

I've contemplated making up a mounting structure for the right side muffler hanger and adding my
Acerbis number plate tank to it on the side like I did on my TE510.

 

[capt42104]

I love my Rotopax set up sofar! I have about 1000 miles of hard trail riding and don't see any issues with my overloading the tail rack. When a reasonably priced extended range fuel tank becomes available, I will go to that.

 

[twolane]

I love my Rotopax set up sofar! I have about 1000 miles of hard trail riding and don't see any issues with my overloading the tail rack. When a reasonably priced extended range fuel tank becomes available, I will go to that.

Got any pics?

 

[capt42104]

Got any pics?

 

[Huskyfly]

Nice, how "jiggly" is it offroad? Personally I think they should hire a welder and fire the riveter.
I wonder if they could come up with a mount to put the can down and back more, kinda tucked under the muffler but clearing the swingarm. I guess a single exhaust would make it easier...
Only other option I've seen is a Rotopack mount installed on a tail rack.

Let us know how it holds up

ETA:

Which rear rack setup do you have here?

 

[RDTCU]

Which rear rack setup do you have here?

Ask capt42104, I stole his picture, but I think it was the Husky rack.

 

[Huskyfly]

Ask capt42104, I stole his picture, but I think it was the Husky rack.

Yeah, I found it later. The weird thing is that the Touratech rack looks ALMOST like the Husky rack....BUT doesn't have the grab rails.......and the Husky ones CHEAPER?! Nobody seems to have the Husky Rack in stock, totally sold out everywhere it seems?!

 

[capt42104]

Yo, It is a Tourtech, but i think it is identical to what Husky now carries. It has very nice grab rails too. As far as it being jiggly off road, well it is very solid. just did 100 miles of this stuff!

 

[Xcuvator]

Go to single exhaust and re-purpose the unused muffler into a fuel cell. will look stock and hold a gallon. People will crap themselves when you remove your "muffler" and dump gas from it.

You have to be kidding? Looks like to me that a Jeep can would fit right on the PegPacker setup.
Much simpler, and more capacity for looooooooong rides...
I guess the muffler tank would be cool though.