Reynolds Rack #241, w/ FIVE custom braces/fuel cell retainer brackets & FuelSafe CT105 5-gallon fuel cell

I wanted to add additional fuel capacity to the bike, to increase my flexibility in choosing when to stop for refueling. The choices were:

• Stock tank expansion
• Fuel Cell on passenger seat area
• Fuel Cell on luggage rack

The first option was bypassed both for aesthetic reasons and because it provided a limited increase in fuel capacity compared with the other two options. It was also the most expensive option.

The second option required the most re-work of the stock platform (solo seat and custom tail setion), and was also quite expensive.

The last option gave the most fuel capacity for the least cost, but at the expense of the worst mass centralization. Nevertheless, I chose to implement a rack-based fuel cell, in keeping with my budgetary constraints and my desire to make minimal changes to the stock bike.

The fuel cell platform is based upon a Reynolds Rack, P/N #241. The cell itself is a FuelSafe Fuel Cell #CT105, with their SF4X6A filler plate, a 90 degree -6 AN top vent, and a –6AN bottom/rear/left 90 degree fuel pickup.

Since the K11RS is fuel injected, setting the auxiliary fuel system up as a transfer-based system was the easiest and most logical approach. The system is designed to use the stock fuel tank/pump as the primary feed for the injector system, with the auxiliary fuel being pumped into the main tank when the main tank empties.

To accomplish the fuel transfer, a NAPA Fuel Pump, #2P74019, is mounted below the Reynolds Rack on the tail section, and is fastened to the stock luggage rack. The fuel output from the cell passes through a Fram fuel filter, #G3606, into the pump, and is pushed forward thru 5/16" fuel injection-rated fuel line. A manual shut-off valve is placed in-line, just below the left sidecover, to allow the fuel connection between the cell and the main tank to be physically shut off. (This is often necessary to prevent "bleed-down" of the cell into the tank; should the tank be full when such a siphon occurred, the tank would overflow out the vent lines and dump gasoline all over the pavement under the bike.) The shutoff valve is a Tempo Marine shut-off valve, P/N #303-FSO, and us UL-rated for gasoline usage. The fuel cell is vented from the top, and an elbow vent line was constructed from a combination of 3/8" and 7/16" breather hose, along with a PCV 90 degree connector. The fuel pump is activated by a Cole Hersee Marine Rocker switch (lighted when ON), P/N #56327-01. The switch is located on the stock dash pad, just to the left of the ignition switch. It is wired from the front parking lamp circuit, and is used to activate a relay which in turn drives the pump. This ensures that the pump has its own fused power source, and the pump cannot be activated unless the ignition is ‘ON’.

The fuel cell is placed onto a set of rubber mats that sit upon the Reynolds Rack. Rubber mats were chosen to ensure a high-friction surface between the cell and the rack. The rack was augmented with three custom brackets (one per side and one in the rear) which positively locate the cell onto the rack. Additionally, a set of brackets were fabricated to tie the front of the rack directly to the bike’s subframe, eliminating the likelihood that the rack would rock fore-n-aft under the load of the fuel cell. (All of the brackets were designed to use the holes provided on the rack for bungee tie-downs, eliminating the need to modify the rack itself.) Finally, two 1" nylon web straps are used to vertically secure the cell to the rack .