KLE 500 Fuel capacity increase modification discussion

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Panjo

Race Dog
Joined
Mar 11, 2010
Messages
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Location
Amsterdam NL
Bike
KTM 990 Adventure
Ok, So I have this KLE 500 and I love the bike. However, the Small fuel tank is a concern as I want to do some long distance cross border flights in the not too distant future. Now, saying that,I know some people are going to say, well, just carry a jerry can, or fuel bladder with you. Well, yes, I agree that is the simplest answer, but, I like a challenge and it would be nice to fit a auxilary solution that does not involve the rider having to stop and siphon fuel from one tank to another.

So, here's my 4 possible areas of modification and I'd appreciate some feedback from you more practical down to earth dogs.

1. I have access to a spare KLE 500 tank. I believe with the right artisan (Sheet metal worker), that the tank could be cut horizonatally and plate added to raise tank height and increase the capacity.


2. As I will be riding with no pillion, I figured at least half the seat (rear) is not used. I could have a new seat manufactured that contains the rear half made into a auxilary tank, with plumbing into the fuel tap.


3. 2 x 3l Header tanks, from Ascerbis, placed inside the fairing, on the left and right, with plumbing into the fuel tap.


4. 2 x 3l Header tanks, atatched to the Crash bars, between the bar and the bike. With plumbing into the fuel tap.


Option 1 Pros
From a safety aspect (Fuel handling) I think this is the best. Fuel all kept in one place. No extra plumbing required.
Option 1 Cons
Skilled artisan required to modify tank.(Anybody know one?) End result could look funny ? May mess with the bikes handling, by increasing tank height.

Option 2 Pros
Does not change the aesthetics of the bike. Better to have weight distributed over the back axle? fuel is kept away from hot engine! Easy access to fill.

Option 2 Cons
Specialist required to manufacture? What materials, Aluminium? or take a spare seat and cut in Half, and add header tanks. Plumbing needs to be added to gravity feed to Fuel tap.

Option 3 Pros
Does not change the aesthetics of the bike. Protected from the elements

Option 3 Cons
Access is restricted by fairing and would require modification of bike tupperware. Plumbing to tap may require electric pump to feed.

Option 4 Pros
Access is easier.  

Option 4 Con
Not protected from the elements. Would require some modification to the Crash bars for attachment and also for protection of tanks. Weak point would be plumbing, somewhat exposed. Would require a fuel pump. Increased risk of puncturing the tank in the event of a fall and causing a fire.

Are these the only options? And before anybody mentions it, I don't want to by a another bike with a larger tank  :lamer:

Looking forward to the comments!
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