My attempt to retrofit the bigger OEM fuel tank into 2013PCX
Moderator: Modsquad
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
Re: My attempt to retrofit the bigger OEM fuel tank into 201
Wait...
Dremel with a smaller wheel than pictured.
Now
Next, hammer time.
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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 (134.01 KiB) Viewed 3274 times
-
- IMG_20180104_001403043.jpg (137.73 KiB) Viewed 3274 times
-
- IMG_20180107_132113767.jpg (138.01 KiB) Viewed 3274 times
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
Re: My attempt to retrofit the bigger OEM fuel tank into 201
View of brackets that where cut, my shoddy new brackets and paint.
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- PCX150Rider
- Frequent Poster
- Posts: 1832
- Joined: Tue Jan 17, 2017 1:56 pm
- Year: 2017
- Color: White
- Location: Old Saybrook, CT
Re: My attempt to retrofit the bigger OEM fuel tank into 201
Intriguing puzzle. . ..
Amazing!
Amazing!
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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.
Gil
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
Re: My attempt to retrofit the bigger OEM fuel tank into 201
The plastic panels might be the most difficult post of the puzzle.PCX150Rider wrote:Intriguing puzzle. . ..
Amazing!
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- pcx888
- Regular User
- Posts: 171
- Joined: Sat Nov 25, 2017 9:31 pm
- Year: 2011
- Color: pearl white
- Location: Hacienda Heights, Cali
Re: My attempt to retrofit the bigger OEM fuel tank into 201
Hopefully it works. Awesome job.
2011 White PCX
Michelin Tire City Grip Front and Rear
Aftermarket Thai Seat.
JDM Front lights and Rear Lights and Fender.
NCY Variator, And Face and 13 Dr. pulley sliders.
Rear NCY 1000 contra spring.
NCY Textured clutch bell.
Michelin Tire City Grip Front and Rear
Aftermarket Thai Seat.
JDM Front lights and Rear Lights and Fender.
NCY Variator, And Face and 13 Dr. pulley sliders.
Rear NCY 1000 contra spring.
NCY Textured clutch bell.
-
- Forum Benefactor
- Posts: 2857
- Joined: Sun Dec 29, 2013 11:43 pm
- Year: 2014 125 (LED)
- Color: White
- Location: London, England
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
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
Re: My attempt to retrofit the bigger OEM fuel tank into 201
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.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
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.
Thankspcx888 wrote:Hopefully it works. Awesome job.
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- WhiteNoise
- Official Moderator
- Posts: 8784
- Joined: Mon Nov 07, 2011 11:15 pm
- Year: 2015 PCX 150esp
- Color: Pearl *White*
- Location: L.I. N.Y.
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
"Hammer Time!"
I like that
Location, Year & Color - Please enter Yours today!
How? Log in. Click the User Control Panel button (top right of any page). Upon destination, click Profile in left column. Look >See the questions? Please Complete. We Thank You
How? Log in. Click the User Control Panel button (top right of any page). Upon destination, click Profile in left column. Look >See the questions? Please Complete. We Thank You
- Mel46
- Forum Benefactor
- Posts: 6959
- Joined: Tue Nov 13, 2012 5:13 pm
- Year: 2013
- Color: red PCX
- Location: Dallas, Ga USA
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.
Currently own:
Red 2013 Honda PCX150
Givi tall windshield & tailbox - Lots of extra lights
Custom seat from Thailand - Bad Boy Airhorn
Takegawa Lowering Shocks - Michelin City Grip Tires
Headlight assy upgraded to LEDs w/HS5 main bulbs
NCY variator, drive face, and rollers
Red 2013 Honda PCX150
Givi tall windshield & tailbox - Lots of extra lights
Custom seat from Thailand - Bad Boy Airhorn
Takegawa Lowering Shocks - Michelin City Grip Tires
Headlight assy upgraded to LEDs w/HS5 main bulbs
NCY variator, drive face, and rollers
- PCX150Rider
- Frequent Poster
- Posts: 1832
- Joined: Tue Jan 17, 2017 1:56 pm
- Year: 2017
- Color: White
- Location: Old Saybrook, CT
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".
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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.
The end is near.
That saying definitely fits.PCX150Rider wrote:Perhaps there is some truth to the old saying "Smash to fit. . .Grind to match".
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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 (66.25 KiB) Viewed 3116 times
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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.
On the right side, I had to shave some of the plastic where the wire harness passes by.
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. I need to wash my scoot, it's dirty.
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Mel46
- Forum Benefactor
- Posts: 6959
- Joined: Tue Nov 13, 2012 5:13 pm
- Year: 2013
- Color: red PCX
- Location: Dallas, Ga USA
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.
Currently own:
Red 2013 Honda PCX150
Givi tall windshield & tailbox - Lots of extra lights
Custom seat from Thailand - Bad Boy Airhorn
Takegawa Lowering Shocks - Michelin City Grip Tires
Headlight assy upgraded to LEDs w/HS5 main bulbs
NCY variator, drive face, and rollers
Red 2013 Honda PCX150
Givi tall windshield & tailbox - Lots of extra lights
Custom seat from Thailand - Bad Boy Airhorn
Takegawa Lowering Shocks - Michelin City Grip Tires
Headlight assy upgraded to LEDs w/HS5 main bulbs
NCY variator, drive face, and rollers
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
Re: My attempt to retrofit the bigger OEM fuel tank into 201
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.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.
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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
Gil- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.
- PCX150Rider
- Frequent Poster
- Posts: 1832
- Joined: Tue Jan 17, 2017 1:56 pm
- Year: 2017
- Color: White
- Location: Old Saybrook, CT
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!
Nice job!
- Gil
- Frequent Poster
- Posts: 623
- Joined: Mon Nov 09, 2015 10:20 pm
- Year: 2013
- Color: black
- Location: Watsonville, CA
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!
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.
Gil
- 2013 Honda PCX 150, NCY Variator kit, Dr Pulley 13g Roller weights
- IRC and City Grip tires, LED driving lights, Coroplast top box, MFR exhaust, Daytona Windshield.