Acerbis 6.6 gallon tank install: '08 DR650

Discussion in 'Thumpers' started by SeanF, Oct 26, 2009.

  1. SeanF

    SeanF Long timer

    Joined:
    Jun 11, 2004
    Oddometer:
    2,275
    Location:
    Tucson Arizona USA
    (This is also in the DR650 thread)

    Acerbis offers a 6.6 gallon fuel tank for
    <strike>'92 and older</strike> 1992-1995 DRs. I wanted more capacity than the IMS 5 gallon model, and couldn't see spending $550 for the Aqualine 8 gallon model.

    First, the physical differences between the stock tank and the Acerbis model:
    [​IMG]

    [​IMG]


    We needed a few modifications to make it fit my 2008 model.

    The turn signals are in the way of the tank well before full-lock of the handlebars, so I switched the mounting brackets to opposite sides, and then reversed them. This moved the lights up and forward a bit.
    [​IMG]

    Spacers had to me made for the support bolt that runs across the frame tube. It helps to have a friend with a lathe who isn't afraid to use it.
    [​IMG]

    [​IMG]
    The spacers replaced a pile of washers and other kludgy bits.
    [​IMG]

    Oil cooler and crash guard: The oil cooler has to move forward a few inches. The mounting tab was easily bent by hand. The cooler guard will take more work.

    Oil cooler moved forward slightly; also cut out a section of the oil cooler guard.
    [​IMG]
    [​IMG]

    Fortunately, 1/2" mild steel tubing fits perfectly inside the tubing used for the stock guard. Using a tubing cutter and a bender, I pieced together a new bracket that not only fits around the tank, but provides a little more coverage than the stocker.
    Mock-up:
    [​IMG]

    Another angle:
    [​IMG]

    Brazed and painted (sadly, my skills are lacking in both areas):
    [​IMG]

    The angle of the tank doesn't quite match the angle of the seat, so I cut off the forward section of the pan:
    [​IMG]

    ...and the rear flange of the Acerbis tank is quite a bit thicker than the stocker -- so some tough love with a Dremel tool and a heat gun brings it into shape:
    [​IMG]
    (NOTE: Yes, that is a hole in the center of the rear flange of the tank [above]. We had a discussion about whether that flange was solid or hollow, because if solid it would open up more mounting possibilities. Turns out -- it's hollow. The hole was a test and easily patched.)

    And now the seat foam gets some attention. After this pic was taken I leveled off the front of the foam and cleaned up the sides up front. An angle grinder used LIGHTLY makes a great foam sculpting tool.
    [​IMG]

    The Acerbis tank has two petcocks, and comes with a length of fuel hose and a cheesy plastic tee -- I replaced it with a barbed brass tee.

    Result
    [​IMG]

    [​IMG]


    Next we'll make up some luggage racks from 1/2" CroMo tubing.
    #1
    REALGRAVEROBBER likes this.
  2. leonphelps

    leonphelps TAT/Prudhoe Bay

    Joined:
    Oct 19, 2006
    Oddometer:
    1,046
    Location:
    Waterford CT
    When I had my 6.6 mounted on my WR250F, it ended up blowing out the fork seals while I was on my TAT ride. It gets very nose heavy and the front end plows through the sand/dirt. Very unsteady. I'd think about replacing the front fork springs to something stiffer if you haven't yet.
    #2
  3. SeanF

    SeanF Long timer

    Joined:
    Jun 11, 2004
    Oddometer:
    2,275
    Location:
    Tucson Arizona USA
    Noted. I will probably start messing with suspension once I finish adding a bunch of extra weight. :lol3

    Cheers:freaky
    Sean
    #3
  4. Reposado1800

    Reposado1800 Juicy J fan!

    Joined:
    Dec 8, 2006
    Oddometer:
    5,824
    Location:
    5th and Main
    Isn't it going to be nice to only fill the tank when you feel like it?
    360+ miles to empty.
    #4
  5. B.E. Coyote

    B.E. Coyote (Super-Genius)

    Joined:
    Jul 6, 2004
    Oddometer:
    6,606
    Location:
    Virginia Beach, Va.
    Nice, just picked up an 02 and was thinking about this mod.

    Not sure if it is worth the xtra hassle over the 4.9 gallon for me though. If I can up with a used 6.6 I might decide to give it a try.

    Good work! :freaky
    #5
  6. REALGRAVEROBBER

    REALGRAVEROBBER LEAVING GRAVES EMPTY

    Joined:
    Nov 1, 2008
    Oddometer:
    794
    Location:
    GFY, Montana
    I hear that the fuel petcock attaches to the Acerbis 6.6 with self-tapping screws that only go into the plastic of the tank. Anyone have any trouble with this cheap design, or able to correct me that I am mistaken?
    #6
  7. SeanF

    SeanF Long timer

    Joined:
    Jun 11, 2004
    Oddometer:
    2,275
    Location:
    Tucson Arizona USA
    Correct, that is how the petcocks attach.

    No problems with it in 36k miles/6 years.
    #7
    REALGRAVEROBBER likes this.
  8. jet123

    jet123 Using all my gears

    Joined:
    Mar 15, 2007
    Oddometer:
    6,092
    Location:
    Ft Collins, CO
    There is a bike-specific index over in Thumpers. And there, you will see very few issues have been experienced with this tank / screw set-up.
    #8