Larger Tank for the 1400 with input from Designer

[The1Chef]

yes Designer has big tank info.

ask away

[Designer]

Yes, I liked the appearance of the Stock 1400 tank. IMHO, it is the best looking tank for the 1400.

So I modified it to get more capacity and got about 4 gallons total, netting about 180 miles per fillup. I also increased the reserve so I now get about 18-20 miles from it. And made the Filler Cap much nicer-looking too.

[Night_Wolf]

Yes, I liked the appearance of the Stock 1400 tank. IMHO, it is the best looking tank for the 1400.

So I modified it to get more capacity and got about 4 gallons total, netting about 180 miles per fillup. I also increased the reserve so I now get about 18-20 miles from it. And made the Filler Cap much nicer-looking too.

how?

[Designer]

Yes, I liked the appearance of the Stock 1400 tank. IMHO, it is the best looking tank for the 1400.
So I modified it to get more capacity and got about 4 gallons total, netting about 180 miles per fillup. I also increased the reserve so I now get about 18-20 miles from it. And made the Filler Cap much nicer-looking too.

how?

By using,.............MAGIC!

Okay, I'm pulling your leg.

The basic concept I used was to eliminate as much of the "tunnel" down the middle of the Tank, and to "reverse" the front mounting point.

I use the K&N Pod Air Filters, so the Stock Front Air Filter Box and connecting Rubber Boot are not there and thus the 'Tank Tunnel" recess needed for them both was not necessary any more. So, that "space" in front of the K & N could now be used to hold gas if the Tank were modified.

Plus, I noticed the Front Tank Mount put yet another recess unto the Tank. I reasoned that if the Tank itself had a projection/extension into a newly designed "Receiver/Mount" bolted to the Frame, (instead of that recess) that Tank projection could add even more Fuel capacity.

And it does.

Plus, I took out more of the "Tank Tunnel" from the back of the K & N Filter to the Rear Tank Mount. That lowered the Fuel Cock a bit and so I made an extension to the Pipe inside the Tank begetting a "Reserve" of 18-20 miles (instead of the woefully small stock reserve).

Moving the Gas Cap up and over helped too. Now I have 3.9 usable gallons before reserve.

[The1Chef]

Yes, I liked the appearance of the Stock 1400 tank. IMHO, it is the best looking tank for the 1400.
So I modified it to get more capacity and got about 4 gallons total, netting about 180 miles per fillup. I also increased the reserve so I now get about 18-20 miles from it. And made the Filler Cap much nicer-looking too.

how?

By using,.............MAGIC!

Okay, I'm pulling your leg.

The basic concept I used was to eliminate as much of the "tunnel" down the middle of the Tank, and to "reverse" the front mounting point.

I use the K&N Pod Air Filters, so the Stock Front Air Filter Box and connecting Rubber Boot are not there and thus the 'Tank Tunnel" recess needed for them both was not necessary any more. So, that "space" in front of the K & N could now be used to hold gas if the Tank were modified.

Plus, I noticed the Front Tank Mount put yet another recess unto the Tank. I reasoned that if the Tank itself had a projection/extension into a newly designed "Receiver/Mount" bolted to the Frame, (instead of that recess) that Tank projection could add even more Fuel capacity.

And it does.

Plus, I took out more of the "Tank Tunnel" from the back of the K & N Filter to the Rear Tank Mount. That lowered the Fuel Cock a bit and so I made an extension to the Pipe inside the Tank begetting a "Reserve" of 18-20 miles (instead of the woefully small stock reserve).

Moving the Gas Cap up and over helped too. Now I have 3.9 usable gallons before reserve.

Just shared that....
Thanks Designer

[The1Chef]

you dont happen to have any supporting pictures do you?

[Designer]

you dont happen to have any supporting pictures do you?

Welllll,. .........I might, ...........that is, ...........if Night Wolf wants to see them too. ..........

[Designer]

Yes, I liked the appearance of the Stock 1400 tank. IMHO, it is the best looking tank for the 1400.

So I modified it to get more capacity and got about 4 gallons total, netting about 180 miles per fillup. I also increased the reserve so I now get about 18-20 miles from it. And made the Filler Cap much nicer-looking too.

how?

Ask, And Ye Shall Receive!

First, I made a Template of the Stock Tank's Tunnel



Then fitted it over the Pod Air Filter, Wiring Cables and stuff on Black Thunder. Marking off what I thought were adequate clearances for all such stuff;



Then I fabricated the Sheet Metal to follow the New Profile I drew on the Template;



Then I machined a New Boss for the Aircraft-styled Gas Cap.



I wanted it to be "Frenched" in and Relocated it to the "High Side" of the Tank (when on the Kick Stand.)



Wanting more Fuel Capacity, I "reversed" the Font Tank Mounting so the projection was the Tank, not the Mounting Bracket into a recess in the Tank.;



Then it was simple matter of making a "bracket" that would receive the tanks projection;



With the Tank Fuel Cock now being located much lower, I extended the Fuel Inlet Pipe on it. So in effect, I have more fuel for my Reserve.



And there you have it!

[The1Chef]

Wow....
I didnt think that was a stock tank. Thought you flew it in...

good job man

[The1Chef]

and you gained justbover 1 litre?

[Designer]

Wow.... I didnt think that was a stock tank. Thought you flew it in...
good job man

Thanx for the compliments. It was a fun Project.

Personally, I think the 1400 tank is the prettiest tank.

and you gained justbover 1 litre?

I've forgotten long ago what the useable Gallons of the Stock Tank are so as to compare.

I know that I can get 4 gallons in this one.

[FinTruder]

Where from original tank breathes? In hot day my old tank cap is banging shortly after starting a ride. Does it breathe from key hole? It surely hisses from it in off mode.

[FallenAngel]

Where from original tank breathes? In hot day my old tank cap is banging shortly after starting a ride. Does it breathe from key hole? It surely hisses from it in off mode.

Most of the time they rattle
Yes there is a vent in the cap the hissing may be an obstruction in the cap
Take the cap off and use a penetrating oil in a spray can or compressed air through the key slot to remove an obstruction
Or carb clean and then oil occasionally work the key this will prevent jamming and help to clean the tumblers in the lock
If using an aerosol do it over a clean rag to see what and how much comes out
You may be surprised

[FinTruder]

Yeah, my cap is very tight and hard to put in place AND its jamming now and then. But that sound is weird, like someone throwing rock on it inside the tank. When i lay my hand on it it really kicks. I think those heated gasoline fumes want to come out from snug cap and bang.

[FallenAngel]

Yeah, my cap is very tight and hard to put in place AND its jamming now and then. But that sound is weird, like someone throwing rock on it inside the tank. When i lay my hand on it it really kicks. I think those heated gasoline fumes want to come out from snug cap and bang.

Pressurized fuel fumes is never a good thing in an uncontrolled environment
Try cleaning the cap out
These do rust and can get sticky
You can also use transmission fluid to lubricate the inside of the cap
I like it because it is a light oil and dirt dosnt stick to it as much as the heavy oils
I found it works really well in control cables to

[Designer]

Yeah, my cap is very tight and hard to put in place AND its jamming now and then. But that sound is weird, like someone throwing rock on it inside the tank. When i lay my hand on it it really kicks. I think those heated gasoline fumes want to come out from snug cap and bang.

This condition ties in with the Engine Performance/Exhaust issues you had just posted about in another Thread.

Let's see if after you get the Cap Venting fixed if it changes anything you previously reported on.

[FallenAngel]

This condition ties in with the Engine Performance/Exhaust issues you had just posted about in another Thread.

Let's see if after you get the Cap Venting fixed if it changes anything you previously reported on.

Poorly vented fuel tank causing a lean condition??

[Designer]

Yes, a lack of sufficient fuel delivery due to a partial vacuum in the tank can do that.

[FinTruder]

Yeah, my cap is very tight and hard to put in place AND its jamming now and then. But that sound is weird, like someone throwing rock on it inside the tank. When i lay my hand on it it really kicks. I think those heated gasoline fumes want to come out from snug cap and bang.

This condition ties in with the Engine Performance/Exhaust issues you had just posted about in another Thread.

Let's see if after you get the Cap Venting fixed if it changes anything you previously reported on.

It would make sense. I will buy new cap today and let's see what happens

[Designer]

Yeah, my cap is very tight and hard to put in place AND its jamming now and then. But that sound is weird, like someone throwing rock on it inside the tank. When i lay my hand on it it really kicks. I think those heated gasoline fumes want to come out from snug cap and bang.

This condition ties in with the Engine Performance/Exhaust issues you had just posted about in another Thread.
Let's see if after you get the Cap Venting fixed if it changes anything you previously reported on.

It would make sense. I will buy new cap today and let's see what happens

Well, you can do that,......However, to save your Hard-earned money and save on Valuable Riding Time, let's see what happens when you do what FallenAngel suggests here;

Pressurized fuel fumes is never a good thing in an uncontrolled environment
Try cleaning the cap out
These do rust and can get sticky
You can also use transmission fluid to lubricate the inside of the cap
I like it because it is a light oil and dirt doesn't stick to it as much as the heavy oils
I found it works really well in control cables to

Maybe even try some Penetrating Oil if the Transmission Fluid doesn't seem to be working at first. Then use the Trans Fluid to keep things moving inside the Cap.