Fuel Tank Capacity & Venting
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Thread: Fuel Tank Capacity & Venting

  1. #1
    Member TrailWhale's Avatar
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    Have to ask question that's bothered me for some time. Every time I fill up with gas I get pxxxed about the price, and the E10 that kills performance (when I can't get to the E0 station). But I also get pxxxed about what looks to me like unused tank capacity. My Tdub, probably like every other stock Tdub, has a metal inner collar in the fuel tank; its a bit larger in diameter than the fuel tank opening, and about three inches down into the tank (you know what I mean). The instructions for those who read them say to only fill with fuel to the bottom edge of the collar, doubtless to allow the tank to maintain a column of air under the fuel tank cap, to better prevent any raw fuel from sloshing out the vent hole in the fuel tank cap.



    Why can't I just install a motocross style fuel tank cap with the hole in the center of it and the vent hose sticking up out of the top, and then fill the tank right to the very top of the gas cap rim? I suspect there's as much as a half gallon of unused capacity in the stock tank due to that metal inner collar in the tank, if you do follow the fill instructions.



    I'd actually be willing to make the vent hose so long that it would go over my shoulder and down my back to the absolute rear of the bike. That way any light vapors that actually made it up and over my shoulder would safely exit the scene in the dust trail behind Tdub. After the first rest stop, when the fuel in the very top of the tank has burned off and gets below the level of the metal collar, I could coil up the vent hose and stick it in the space between the bars and the speedometer.



    In fact, couldn't I just use a "two ball tank valve" like here, and (since that vent hose would just suck air) vent the hose back through the bike frame to the swingarm, like the carb vent line?



    Opinions requested.

    - - - Happy Trails, Jim
    Most problems can be solved with a suitable application of throttle!

    2007 Yamaha FZ6 bagger (still miss the TW200)
    2001 TW200 Yuasa YTZ7-S + Tender Jr.; fuel filter; socket head cap screws for seat; homemade rear rack; D2Moto; carb mods (#128; 3x.01; 2-1/2 turns) (sold 2012)
    1993 XT350 (sold)
    1987 TW200 14/55+Oring (sold)
    et al, et al, starting with 1964 Honda 50 Sport

  2. #2
    Senior Member PalmStateCrawler's Avatar
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    I fill it all the way up. The stock cap vents fine and until I get some overflow, I will continue to do so.
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  3. #3
    Senior Member TWBARR's Avatar
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    Quote Originally Posted by JdubSC View Post
    I fill it all the way up. The stock cap vents fine and until I get some overflow, I will continue to do so.


    Agreed I do the same to get the most use out of our little tank. Occasionally I will smell a little gas but the vent does a good job from keeping the gas from sloshing out.

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  5. #4
    Senior Member TW_in_BC's Avatar
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    That inner collar is just a "guideline"...not an actual rule!
    2008 TW200
    Southwest corner of BC Canada

    YouTube channel: Hidden Content

  6. #5
    Senior Member Beewerks's Avatar
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    x4 I usually fill mine to the rim of the tank opening with me pushing the bike into the upright position. Haven't had any problems yet even in 105 degree heat.
    '05 TW200--15/50 gearing, Cyclerack, XT350 tank

    '81 KZ750--project bike

  7. #6
    Senior Member evan's Avatar
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    I fill mine up to very top with me sitting on seat and bike not on kickstand. I don't even get off bike to fill up. just get close to pump and use credit card. I always get every last drop I can in it before I park it in my garage after I ride it since its a metal tank and don't want it to rust and nice to have it fueled and ready to roll for my next adventure. also clean and lube chain when I get home.
    Howsbentley likes this.
    Mike Carter. Woodland, California (NorCal). '89 Tw200 (Black Widow Edition). Blood red Jimbo shield, Cycleracks, Nuvi 500 GPS, Kolpin fuel pack jr., D shield bark busters, 55t rear sprocket, Golden boy front tire, Ricochet shield.

  8. #7
    Senior Member r80rt's Avatar
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    I used a SHARP punch and poked a hole in that guard on my '97, that lets the air out and now I can fill it to the brim.
    Only a fool would attempt it, and God help me, I am that fool!

  9. #8
    Senior Member RodneyReed's Avatar
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    Quote Originally Posted by r80rt View Post
    I used a SHARP punch and poked a hole in that guard, that lets the air out and now I can fill it to the brim.


    How much more gas does that give you? Is it really half a gallon?

  10. #9
    Senior Member darnold87's Avatar
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    My 1989 Tdub doesn't have this gaurd you speek of... I just fill it to within about an inch of the very top (when bike is vertical)... no leaky.
    ~Davey

    '89 TW200

    '94 Suzuki Sidekick

  11. #10
    Senior Member PalmStateCrawler's Avatar
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    Guard? Are you talking a bout the circular "collar"? What good would a hole punch do?
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

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