• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

New 630 Safari tank

ICBiker said:
This is a repeat of my reply from the other Safari thread but have added a couple of pictures of the first tank.

I put a safari on my TE610 and the sealing surface for the fuel pump was very uneven. At first it seemed to seal up fine but after a few days it started leaking gas all over the garage floor. After a few E-mails to JGT they sent a second tank and insisted that I put a new O-ring on with it. After buying a new $43 O-ring from Husky I found that the second tank's sealing surface was not much better than the first. I used the new O-ring and applied a gas tank sealant that I got at Autozone around the outside surface next to the O-ring and it has held for about 10 months with no leakage.

IMG_1890_zpsdd899381.jpg


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Click to expand...

Where did you get the fuel pump protector?I searched the force website but nothing comes up.
 
Dr Klaun said:
...Lastly, what are any of you using for tank bags, if any at all? I've been using the GL Fandango, but it doesn't look like it will work with the tall hump of this tank. I'd really like something with a map case....
Click to expand...

Your GL Fandango should work fine. I have a similar Nomad Rider Sherpa tank bag and it fits great. Love the three outside pockets. GL needs to learn from its knockoff competitor.
http://www.nomadrider.com/sherpatankbag.aspx

Temp081.jpg


Even "The Man" liked it, haha

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_
 
Nice... I won't open the can of worm of the Nomad vs. GL, but I will say that I support the local company!

Back on topic - does the tank bag set up like that pinch the fuel breather hose coming out of the gas cap?

Big Dom - do you know what material you used for that thicker gasket in case I have to go that route?

Thanks!
 
Dr Klaun said:
Back on topic - does the tank bag set up like that pinch the fuel breather hose coming out of the gas cap?
Click to expand...

I have always used a locking vented gas cap without breather hose but by eyeballing it I don't think hose would be pinched by my bag. Not sure for the Fandango bag though as I don't know the size difference.

_
 
IMHO go to a good car parts store and get some of the thickest gasket material for gas you can. Cut yourself a gasket and mount it up. Should seal better than an o-ring, be much more reliable than some tube sealer and you could make several for cheap. I think there is a closed cell fuel resistant 1/4 neoprene material that would compress and fix that issue. I don't know why they don't just come with something like that to solve this obvious issue. Additionally is there any way you could sand the pump area flat with a flat board and sand paper? Or are the inserts keeping you from doing so?
 
Thanks - I'l check out a couple of places here and see what they've got. Always online available...
In regards to the tank, I haven't really looked at it yet, just getting ideas in case of an issue. I may go with the thicker gasket to start with as I hate to have to stop and deal stuff like this while everything is pulled apart. I read of many folks having the sealing issue, so would rather not have to get everything buttoned up and then take it all apart again.

I'm planning on verifying that the mounting plate area is flat and will flatten it if it's not. The word is that the plastic material is roughly 3/16" thick (may be more at this spot?), so that shouldn't be an issue. In looking at the pic's posted above, it looks like when the bolts are tightened, they flex the plastic where they're "sucked" into the fuel pump flange, vs. the plastic areas between the bolts. I could see where this could create uneven pressure on the gasket.

I also may go with the metal quick-disconnect mod to the fuel pump just to take care of that too, though I haven't had any issues with the plastic ones. I like that protector plate shown at the fuel pump on one of the previous poster's pic's - I'd like to see how that mounts, as I've got a bunch of Alum. kicking around I can fab from.
 
I can say for certain that the surface was this uneven before the bolts were tightened and you can not sand it any flatter due to the inserts already being flush with the plastic surface. The pump guard that you see is part of the safari tank kit for the 610, probably not included with the 630 due to the pump mounting location.
 
I have a Safari Tank for my 630. I was recently doing some wrenching on the bike and one of the threaded inserts for the cross-over bar on the front of the tank has spun. Any ideas on how to repair it? What epoxy will bond to the plastic of the tank? Where can you get replacement inserts? Thanks!
 
bmah said:
I have a Safari Tank for my 630. I was recently doing some wrenching on the bike and one of the threaded inserts for the cross-over bar on the front of the tank has spun. Any ideas on how to repair it? What epoxy will bond to the plastic of the tank? Where can you get replacement inserts? Thanks!
Click to expand...

That'll be a tough one. I would contact Justgastanks and/or Safari first before doing anything. They might be able to help now, but once you start experimenting they'll probably not be willing to.

I saw that potential weak point and put anti-seize on those inserts before install and everytime I remove the bolts. Don't overdue the torque either.

_
 
SilverBullet said:
That'll be a tough one. I would contact Justgastanks and/or Safari first before doing anything. They might be able to help now, but once you start experimenting they'll probably not be willing to.

I saw that potential weak point and put anti-seize on those inserts before install and everytime I remove the bolts. Don't overdue the torque either.

_
Click to expand...
Unfortunately, the problem started when I had some work done in a shop last Fall. I thought that the mechanic had it squared away. I always grease those bolts and start them by hand before tightening them. I sent a MSG to Aqualine a few days ago, no response so far.
 
that o-ring looks like it worked a treat. kelly's on the right track. corks good too if the surfaces are flat and hard.

try a gasket made from an HD tube if that gap ever gets any wider. make a few, pop one in the pack, plus some extra. HD tubes make killer gaskets!
 
Installed. Took a little work to tie my fuel pressure gauge into the new line. Trying some different 630 lettering. Man, how cool is an off-road bike w/ 300 mile range...

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Anyone know what the mount threads and moulding are for on the left (from the front) bottom of the tank?
Mick.
 
Dynobob nice looking graphics.
I just brought a black safari. Mustn't be popular i got it for $200 less than the list price.
Hopefully with a bit of work it won't stay black for long.
 
Cleaned the tank w/ windex and brake cleaner. We'll see. If I have to replace them once a year I will. Some here have had them on for a while...



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DYNOBOB said:
Cleaned the tank w/ windex and brake cleaner. We'll see. If I have to replace them once a year I will. Some here have had them on for a while...

.
Click to expand...

It is just that I have seen some bubble and peel due to gas vapour leaching through the plastic (that is why most sticker kits are perforated).
 
WickedWill said:
Dynobob nice looking graphics.
I just brought a black safari. Mustn't be popular i got it for $200 less than the list price.
Hopefully with a bit of work it won't stay black for long.
Click to expand...
Was that directly from Safari? At that type of discount, I am willing to play about with stickers.
 
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