The Honda PCX / Honda Forza / SH Forums
http://hondapcx.org/

My attempt to retrofit the bigger OEM fuel tank into 2013PCX
http://hondapcx.org/viewtopic.php?f=9&t=8052
Page 2 of 3

Author:  Gil [ Fri Jan 05, 2018 8:06 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Wait...


Dremel with a smaller wheel than pictured.

Attachment:
image-20180105_162931.jpg
image-20180105_162931.jpg [ 91.3 KiB | Viewed 233 times ]

Now

Attachment:
IMG_20180105_164957151_LL.jpg
IMG_20180105_164957151_LL.jpg [ 134 KiB | Viewed 233 times ]

Next, hammer time.

Attachment:
hammer-time.jpg
hammer-time.jpg [ 60 KiB | Viewed 233 times ]

Author:  Gil [ Sun Jan 07, 2018 6:02 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Here are a couple pictures of my progress. Will do a How to guide later.

Attachments:
IMG_20180105_181809426.jpg
IMG_20180105_181809426.jpg [ 134.01 KiB | Viewed 213 times ]
IMG_20180104_001403043.jpg
IMG_20180104_001403043.jpg [ 137.73 KiB | Viewed 213 times ]
IMG_20180107_132113767.jpg
IMG_20180107_132113767.jpg [ 138.01 KiB | Viewed 213 times ]

Author:  Gil [ Sun Jan 07, 2018 7:30 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

View of brackets that where cut, my shoddy new brackets and paint. :)

Attachment:
IMG_20180107_132636342_LL.jpg
IMG_20180107_132636342_LL.jpg [ 117.32 KiB | Viewed 211 times ]

Attachment:
IMG_20180107_132206566_LL.jpg
IMG_20180107_132206566_LL.jpg [ 117.63 KiB | Viewed 211 times ]

Attachment:
IMG_20180107_145257261.jpg
IMG_20180107_145257261.jpg [ 198.97 KiB | Viewed 211 times ]

Author:  PCX150Rider [ Sun Jan 07, 2018 7:39 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Intriguing puzzle. . ..

Amazing! :geek:

Author:  Gil [ Mon Jan 08, 2018 8:14 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

The tank is in and it looks like everything else will bolt on with no issue, we will see.

Attachment:
IMG_20180108_045633678.jpg
IMG_20180108_045633678.jpg [ 194.56 KiB | Viewed 202 times ]


Gil

Author:  Gil [ Mon Jan 08, 2018 8:40 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

PCX150Rider wrote:
Intriguing puzzle. . ..

Amazing! :geek:


The plastic panels might be the most difficult post of the puzzle. :D

Gil :lol:

Author:  pcx888 [ Mon Jan 08, 2018 6:16 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Hopefully it works. Awesome job.

Author:  iceman [ Tue Jan 09, 2018 6:34 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Is the fuel cap going to be at a steeper angle than usual (will the pastics fit around that) - trying to make sense from the pics :)

Author:  Gil [ Wed Jan 10, 2018 2:28 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

iceman wrote:
Is the fuel cap going to be at a steeper angle than usual (will the pastics fit around that) - trying to make sense from the pics :)


It doesn't look like it, but I won't know until I start putting those panels back on. There are little details like extending the fuel pumps wire harness, so that it's slack is like stock, that come up as I continue assembling it. I'm cleaning up some wiring I added to the scoot at the moment, so assembly has slowed for now. I'm wiring up the LED drivers for the headlights and the arduino controlled daytime running lights. It's much easier to do electrical wiring now that all the panels are off.


Here is the stock fuel pump harness. It's stretched a bit too much, so I extended it to avoid future problems. The picture is of the stock harness.

Attachment:
IMG_20180108_161844333.jpg
IMG_20180108_161844333.jpg [ 137.69 KiB | Viewed 162 times ]


pcx888 wrote:
Hopefully it works. Awesome job.


Thanks 8)

Gil

Author:  WhiteNoise [ Wed Jan 10, 2018 1:06 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Kudo's to you Gil! By the Way....You Crack Me Up!
"Hammer Time!"
I like that :D

Author:  Mel46 [ Wed Jan 10, 2018 1:17 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

I have to say, that was an amazing job you did! Even if the panels don't fit, just being able to get everything working is a feat in itself. I hope everything connects together. Keep us informed.

Author:  PCX150Rider [ Wed Jan 10, 2018 2:56 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Perhaps there is some truth to the old saying "Smash to fit. . .Grind to match". :lol:

Author:  Gil [ Thu Jan 11, 2018 3:53 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Thanks everyone, I'm happy with the results so far.
The end is near. :)


PCX150Rider wrote:
Perhaps there is some truth to the old saying "Smash to fit. . .Grind to match". :lol:


That saying definitely fits. :lol:

Author:  Gil [ Thu Jan 11, 2018 8:48 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Fuel pumps


The fuel pumps are only different on how the fuel sender is arranged and the pickup screen. Here is a picture of them side by side.


Gil

Attachments:
image.jpeg
image.jpeg [ 66.25 KiB | Viewed 41 times ]

Author:  Gil [ Fri Jan 19, 2018 1:26 am ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

The scoot is back together


It took me a while to get it back together, as I was working on cleaning up some electrical wiring that I did.
I had assembled most of the panels onto the scoot at the beginning of the week, but soon found out that I needed to shave more plastic from the side panels that come in contact with the tank. I also over loosened the intake valve, so I had to redo that.

Side Panels


In the following pictures you will see the final look of the side panels. I needed a couple of millimeters shaved of both sides.
All the panels bolted back up like OEM. I was planning to add some electrical tape between the panels and the tank so that the paint on the tank wouldn't be rubbed off, but forgot to.

Attachment:
IMG_20180117_170920149.jpg
IMG_20180117_170920149.jpg [ 88.1 KiB | Viewed 51 times ]


On the right side, I had to shave some of the plastic where the wire harness passes by.

Attachment:
File comment: right
IMG_20180117_170515141.jpg
IMG_20180117_170515141.jpg [ 89.8 KiB | Viewed 51 times ]

Attachment:
IMG_20180117_170457578.jpg
IMG_20180117_170457578.jpg [ 69.64 KiB | Viewed 51 times ]

Fuel line


When I plugged in the original fuel line, it stretched a bit too much for my liking. I added a bit of slack by bolting the fuel line mounting bracket, close to the gas tank, more towards the inside and twisted it a bit. I believed that it helped, but I'm still concerned.
I did buy the fuel line from the 2015 model year, but it was a bit too long. It turns out that not only is the spout from the fuel pump assembly different, the fuel injector is too, the fuel injectors spout points back towards the rear tire. I left the original fuel line installed. I'll be checking the fuel line for defects on future maintenance checks.
Attachment:
IMG_20180117_155849136_LL.jpg
IMG_20180117_155849136_LL.jpg [ 122.61 KiB | Viewed 51 times ]


I need to wash my scoot, it's dirty. :)
Gil

Author:  Mel46 [ Fri Jan 19, 2018 12:59 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Is it fully assembled and running yet? I am amazed that you were able to reassemble the bike after all of the modifications done in order to get the gas tank to fit. Have you started it to make sure it runs now? You have definitely done something that most of us would not/could not do.

Author:  Gil [ Fri Jan 19, 2018 2:18 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Mel46 wrote:
Is it fully assembled and running yet? I am amazed that you were able to reassemble the bike after all of the modifications done in order to get the gas tank to fit. Have you started it to make sure it runs now? You have definitely done something that most of us would not/could not do.


It idles Mel46. Everything that plugged into the stock tank also plugged into the newer tank. The fuel pump harness was a bit short along with the fuel line that was a bit too short , but those two issues where addressed.I will go on Test ride today and fill the tank, as it's close to empty. I'm hoping that I don't have any squeaking from the modified plastic panels. :D

Gil

Author:  Gil [ Fri Jan 19, 2018 6:39 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Went on a 50 mile ride and all is good except for the fuel gauge that meters the fuel level differently, i'll have to keep an eye on it too learn it's patterns.


Filled up 1.7 Gal

Attachment:
IMG_20180119_132602269.jpg
IMG_20180119_132602269.jpg [ 37.66 KiB | Viewed 29 times ]


Gil

Author:  PCX150Rider [ Fri Jan 19, 2018 7:45 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

Did you end up installing the 2015 fuel line and just cutting it to fit?

Nice job! 8)

Author:  Gil [ Fri Jan 19, 2018 7:54 pm ]
Post subject:  Re: My attempt to retrofit the bigger OEM fuel tank into 201

PCX150Rider wrote:
Did you end up installing the 2015 fuel line and just cutting it to fit?

Nice job! 8)



I left the original one on, I just added more slack by adding spacers to one of the fuel line mounting brackets.
I think it will be OK.

I mounted the bracket circled in purple to the inside of the chassis mounting point and added a spacer. I also twisted it counter clockwise a bit. I don't have a before and after unfortunately.

Attachment:
IMG_20180117_155849136_LL.jpg
IMG_20180117_155849136_LL.jpg [ 169.24 KiB | Viewed 25 times ]


Gil :geek:

Page 2 of 3 All times are UTC - 5 hours
Powered by phpBB® Forum Software © phpBB Group
http://www.phpbb.com/