Fuel Filler Modifications

Emoto

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Similar to the earlier generation R1200GS, the 2013 GS-W has a long filler neck that reaches several inches down into the tank. This long filler neck impedes the rider's ability to quickly fill the tank all the way to the top. Unlike in the earlier generation, the new one is not a soft rubber piece that can be removed with needlenose pliers. I am sure that this long filler neck serves some valid purpose, perhaps even safety-related. For that reason, I do not advocate these modifications and present them for entertainment only. If you do these mods, I accept no responsibility for the consequences. :cool:

The upside of making these mods are that it is easier to fill the gas tank all the way up, which may extend your range somewhat.

So...

Remove the 6 bolts from around the fuel filler. I also found it easiest to remove the tank center panel. You can't see them in this picture, but there are a couple of hoses attached under the filler assembly. When you pull up on the filler assembly, those hoses need to move, and I think the tank panel blocks them a little, making it more difficult with the center panel in place.

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It will take a little careful wiggling, but eventually the assembly will pull out. It will not require a lot of force, so exercise caution.

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Grasp the lower filler neck, twist a bit and pull down to separate. Note that when you reassemble, the rubber gasket must be positioned so one of the mounting bolts can pass through a hole molded into it.

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One good way to keep them lined up is to slip the bolt through beforehand.

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If you want to make the second mod and drill an air relief hole in the part of the filler neck that is not removed, do it before reassembling.

I recommend using something like a spring-loaded center punch to dimple the plastic in order to provide your drill bit a good start without skating all over when you apply force. About a half inch down, or roughly the same height as the notch tab has been suggested.

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Easy enough to drill a small hole after dimpling. I used a 3/16" bit. Having a shop towel spread out over the tank helps to prevent any debris from falling into the tank. Be sure to clear out the inside of the neck of any lingering drilling debris.

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Then, just bolt it all back to the tank and re-affix the center panel. Remember, those bolts that hold the gas cap and filler neck assembly do not need a lot of torque; be gentle with them.
 
Remove before drilling

I don't think I would drill any holes over fumes from a fuel tank great mod but drills tend to spark whilst in operation maybe 1 in a million may ignite the fumes best to remove it and drill on the bench
Not knocking your method chances are it would be ok :beerjug:
 
Very nicely put together, and good photo's, what can we get you to do next, a workshop manual perhaps!

Good stuff!

Thank you!
 
Glad to do it. I am not the first to make these mods, so all I did was document them when I did them. Regardless, if it helps, I am happy. :beerjug:
 
I'd be curious whether European bikes have the same "outer, extended filler neck" that can be taken off or whether it's one of those other most intelligent US inventions, like the Charcoal Canister.

So, if someone in the UK could check - it would be interesting.
 
I also put a post on here about drilling the filler neck, some time back in April or May. Well worth doing!

I think the filler extension is the same on all bikes.
 

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Good photos, I did mine when I got the bike although I left the extension on. Works a treat, have done it to all my BMW!

This sort of post are great for people thinking of doing a mod but need a bit of help
 
Does anyone know how much extra fuel or range you get? Ive never run out fuel yet. . . But never say never.


As you were. Wrong bike. The joy of using my mobile. . .thoght i was in the hexhead bit. Doh.
 
Does anyone know how much extra fuel or range you get? Ive never run out fuel yet. . . But never say never.

I'd say 1 to 1.5ltrs more fuel in the tank. Does not sound much but it makes a difference, I do think the actual volume of the tank is around 21.5 -22 ltrs. It also, as Emoto says makes filling much quicker.. :-)
 
Note that my original post contains an error in describing how to align the gasket!

It should be like this instead, but I can't seem to edit it.

Grasp the lower filler neck, twist a bit and pull down to separate.

Note that when you reassemble, the rubber gasket must be positioned so that a hole in the tab on the gasket fits over a red protrusion, and also that the gasket has a tab that fits into a slot on the filler surround. I believe that the hole in the red protrusion is to allow fuel vapor to travel to the canister, but have not verified. My thanks to TBob for pointing out the error in my original post!

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great mod
I had this on my 2005 1200gs
I will now do it on my 2013 gs lc.

is it also possible to turn the fuel filler cap around so that when you open it it opens towards the handle bars instead of the rider,
so it makes filling up easier when you are sitting on the bike?

groeetings Emile
 
Interesting.

Instead of drilling a hole in the filler extension, why not just hacksaw the whole thing off?
 


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