Ridiculous way to expand fuel tank capacity on Yamaha XT660Z

By Trail Knights + Roy Reisefuehrer

www.trailknights.com

This is one of the cheapest and most effective mods, I have ever done to my
XT660Z. Even though XT’s tank is big enough to visit 10 Starbucks coffee shops
without a refuel – on a long trip or tour – there is always a need for a bigger fuel
tank, and this mod – does just that!
When fueling up, it looks like Teneres tank will fill up to the top, but since the
filler neck is so low, there is always going to be a massive air pocket. That air
pocket is not vented and could easily fit another liter of fuel! How cool and silly is
that at the same time!

So here is the idea – to make a small hole to help air to escape and let the fuel
take its place and for this mod we will need only two things :
1. Size 4 allen key to undo 4 bolts to remove the fuel cap (only 3 bolts on the
outer ring and 1 under the cap), and
2. 5-8mm drill bit and hand operated drill or something similar.
I strongly advise not to use electric drill as fuel fumes, air and sparks do
not go well together in an uncontrolled environment. So stay away from
those for your own safety.
What I do advise – get some paper towel, roll it in a way that it shapes like a
small bowl and plug the filler hole with it – that way all the shaving will come out
with the paper towel, and none of it will fall inside of the tank. But if you drop
some – that is fine – fuel filter inside of the tank won't let it go far anyway.
Making the hole itself is easy, as plastic is as soft as butter. For that I used a
stepper drill bit mounted on the screw driver- steps on the drill bit also ensured
that I will not go too deep in and out through the other end too!
The best place to make a vent – just under the metal ring – inside of the cutout
for the locking mechanism!
Once done, I would suggest to spray some WD-40 or something similar down
the drain hole on the right side, just in case it got clogged up with dirt over the
time, but be sure to catch all liquid on the other side of the pipe (other end is
near the brake pedal).
And that’s about it, easy mod, costs nothing, and one day that extra fuel (about
1 liter) might just save you from being stranded (or pushing your bike to the
garage)!

Why should I do this?

– about1 liter more fuel
– faster fueling

https://www.trailknights.com/ridiculous-way-to-expand-fuel-tank-capacity-on-yamaha-xt660z/