Jump to content

Fuel Tanks & Mods


Recommended Posts

Just got my new fuel tank in, wow, what a long filler neck :D , I guess things do improve with age, no wait, it's the newer the better, oh I just don't know, guess it really doesn't matter. Take a look at the photos, 2684655760104282158HQdBga_th.jpg, just for fun, I'm going to design & build a capacitive fuel gauge sender for it and make mod similar to flatbed's so the engine doesn't die when going down hill with low fuel. I'll take more photos

Link to comment
Share on other sites

Shop battery chargers at ChromeBattery.com
  • Replies 107
  • Created
  • Last Reply

Top Posters In This Topic

Pulled the old tank & took the fuel gauge apart to see what makes it tick. It turns out that it has 5 reading, empty for the last 2 inches, 1/4 for about 1 1/2 inches, 1/2 for about 1 1/2 inches, 3/4 for about 1 1/2 inches and full for about 2 inches. Some other detail are: when full the resistance is 3 ohms and .3 volts when empty it has 110 ohms and 4.6 volts. It is grounded internally, poorly in my opinion, mine had started leaking if I stacked the tank, so I epoxied it to seal it up.


As the gas level rises, a magnet floats up closing the reed switches, there is a stop for the float about 3/4 inch from full.

Link to comment
Share on other sites

My sending unit stopped working a couple of months ago. Joyner would not replace but would sale me a new one, but only guaranty the new one for a month. The thing cost nearly $90. I said forget it. My dealer tried to repair and did sort of. Since I have a front hood that opens, I am installing a simple sight gauge or replacing with a simple sending unit with a float arm. I know of a couple other people who's gas gauges don't work. Personally this is one item that I would call over built/engineered and a piece of junk.

rocmoc n AZ/Mexico

Link to comment
Share on other sites

kinarfi, if you look at the tank that i change you will see that i moved the mounts closer to the edges of the tank, if you hold the tank on the mounts closest to the filler spout the tank will balance on those two tabs, that means those two tabs are holding all the weight and the others are balancing the tank. Move the tabs to the end of the big part of the tank and make sure you put rubber on the mounts.

Link to comment
Share on other sites

Be careful welding on a gas tank. Have done it but didn't like it. Even if it is empty, it can explode.

rocmoc n AZ/Mexico

I always fill it with water, but not wet the area being soldered/welded and then ignite any vapors prior to starting. At worst, you may get a small woosh as you burn off what ever vapor is left, and since it is controlled and expected, it is relatively safe. If memory serves me, 1 gal gas, properly mixed with air, is equal to 8 sticks of dynamite.



Link to comment
Share on other sites

Kinarfi, I am thinking you will be sorry if you do not move the one set of tabs rearward on the fuel tank, with the added resiviour and the longer filler neck it is almost certain to break. Also you can fill the tank with carbon deoxside while welding, that is what i did. Keep the bottle on it with very low flow and little preassure.

Link to comment
Share on other sites

  • 3 weeks later...
My sending unit stopped working a couple of months ago. Joyner would not replace but would sale me a new one, but only guaranty the new one for a month. The thing cost nearly $90. I said forget it. My dealer tried to repair and did sort of. Since I have a front hood that opens, I am installing a simple sight gauge or replacing with a simple sending unit with a float arm. I know of a couple other people who's gas gauges don't work. Personally this is one item that I would call over built/engineered and a piece of junk.

rocmoc n AZ/Mexico

I've been working on Rocmoc's gas gauge sender unit, waiting a part, and drew up the schematic for the Troopers with a front gas tank. Not to be disagreeable, but these things are very simple in their design and construction. Their biggest problem, IMO, is the red seal where the wires come out. The under seat gauges indicate by 1/4s and front tanks indicate by 1/8s.


Link to comment
Share on other sites

I was talking to turbodude, Scott of Unleashed Motor Sports about gas tanks and he mentioned to me that the new tanks have a baffle in them between the gauge / filler pipe area and the rest of the tank, so I looked and of course, he's right. Interesting IMO. And since I couldn't stick my head in to look at the baffle, I stuck my camera lens in through the fuel gauge hole.20081219_06.jpg

More photos at http://s481.photobucket.com/albums/rr180/Kinarfi/

Played around with photobucket and think I like webshots better, just my opinion.

Link to comment
Share on other sites

  • 3 weeks later...

Well damn, I have been building a clunk pick up for my Trooper's new gas tank and finally got around to cutting a hole to put the clunk in, I found another baffle in the middle of the tank, defeating my idea. Now I have to clean the metal out of the tank and patch the hole.

I have another idea though, and it should be easy build once I find something that will work as a float. Basically, it's an upside down carb float, when gas is present, the float holds the needle valve open, when you head down a steep hill or up, and all the gas moves to forward part of the tank and uncovers the outlet, there is no gas to hold the float up and the needle valve closes and the fuel pump has to pull fuel from the new front pickup which also has this setup. Ideally, you should not run out of gas going up or down when you're nearly empty.

Any input, anybody?

Jeff <_<


Link to comment
Share on other sites

I heard something rattling. Sounded just like a loose tank would. Sure enough, 3 of 4 tabs were broken and the last ready to go. To correct the problem I decided to put a 3/8" peice of plywood with tabs to prevent it from moving under the tank with about a 3/4" layer of polyethylene foam. I then put long threaded studs through the frames tank mount holes and bolted them in leaving mounted threaded studs sticking up. I then made some good solid straps to go over the tanks top. As I tighten it down the foam compresses and provides a solid non moving tank. This was pretty easy and makes for another solution that avoids welding for those that don't have the welder. I could have welded it but I was lazy. I was thinking, gosh, I got to drain the tank, pull all the fittings loose, make provisions so I don't blow myself and the tank up, redo it all and get things reprimed for starting. It was getting late and that sounded like a lot of work.

they quit showing fotos

You will also notice that I put little tabs on my seat belt eye bolts. This keeps the metal clip out of from under the seat when it's being closed. I just pull up on the straps when closing and the rest of the belt stays out to. Before the metal clips would fall down around the eye bolt and not clear always when pulling the straps up.


Link to comment
Share on other sites

I like your straps, Plywood and foam under, when I replaced mine, I did quite a bit of hammering to take out some dents, but with the plywood resting on the frame, I think your set. That's kinda what I was going to do while I waited for my new tank, but then I just padded around and under it.

I like your seat belt anchors too.


Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Weber
      Hello.  Can anyone provide location of fuel pump relay switch.  According to the tech at Massimo it is not in the fuse/relay switch box but mounted near the fuel pump, but I am not seeing it.  Pics would be appreciated also and thank you in advance.
    • By Robert B
      Going down a 20 deg hill engine is holding UTV back. Then something releases like going into Neutral and makes a loud clacking noise. Have to use brake to slow UTV down. Then once level it shifts back into gear. Have done shift extension does not pop out of gear.
    • By NewtoUTV
      We just purchased the Coleman UT400, I put 5 gallons of fuel in the tank and the fuel indicator still reads "empty".  After looking around the fuel tank, I found a tube that is only connected at one end, maybe this is the issue?  I have been looking for a more comprehensive manual that may show how this tube should be connected, no luck.  Looking for help on this issue/issues.  Thank you.

    • By Greg Kilgore
      We all know summer is hot inside the cabs of our SXS. So I've rigged up a couple of fans to help cool down the cab.
      I didn't want to drill the fan's "support rails" into the ROPS (Roll Over Protection System), aka roll bars. So I used water clamps to hold them in place. 
      I just need to replace the wires I ran with bigger gauge. Then finish the wiring to switches, relays, and battery. But the hardest part. The actual mounting of the fans is complete. Also just in case anyone plans on doing this. I may have to only use 1 fan in the middle instead on 2. Due the the draw on the battery.
      The fans are 12", 12V 80W. So I'm figured they were 6.7 amps apiece. Used the WAVe formula to get unknown values Watts=Amps*Volts then solve for unknown. I know the watts and volts from sticker on fan. So just used above formula to get amps. So a 7 amp fuse should be OK and a 10 amp fuse will be good. 
      So pulling 14 amps from the battery all day may be too much for the charging system to keep up with. And I haven't even installed the radio yet. So I will have to test and let you know.
      See pics below.

    • By moto mutts
      Exploring the Grand Canyon's Majesty at the North Rim UTV Fun Run
      Embarking on a journey to the Grand Canyon promises breathtaking vistas, but what we encountered during the North Rim UTV Fun Run organized by UTV Offroad Adventures was nothing short of awe-inspiring. The natural splendor we witnessed transcended our wildest expectations, leaving us in perpetual wonder. 
      The weather was amazing! Upon our arrival at the Kaibab Lodge, we were immediately captivated by the serene setting. Nestled within a picturesque pasture with the national forest as its backdrop, this lodge was a true oasis. From the deck, where we savored cool beverages, we gazed upon the lush green grass and towering trees that stretched into the horizon. The experience was nothing short of breathtaking, offering a refreshing escape from the sweltering heat, and a chance to inhale the pure mountain air. And let's not forget the culinary delights that awaited us—mouthwatering food that was the perfect complement to the surroundings. As the evening wore on, the lodge became a hub of camaraderie, where stories flowed as freely as laughter. The Saturday night raffle event was a highlight, filled with lively exchanges and tales of the day's exhilarating rides.
      Speaking of the rides, both were nothing short of spectacular, showcasing the North Rim of the Grand Canyon's awe-inspiring beauty from every angle. It's a humbling experience to ponder the creation of this national monument, and it truly transports you back in time.
      We were joined by over 70 UTVs and 125 adventurers, all seeking the thrill of exploration amidst nature's grandeur.
      Bright Angel Point: A Scenic Marvel
      One of the rides led us to Bright Angel Point, renowned as one of the most picturesque spots on the North Rim. Sitting at an elevation over 1,000 feet higher than the South Rim of the Grand Canyon, this vantage point offered a mesmerizing panorama. To the east, the stunning Bright Angel Canyon unfolded, while to the west, Transept Canyon stretched majestically. Below, within the canyon, we could hear the roaring of Roaring Springs, a pristine source of water gushing from a cliff face 3,100 feet below the rim. The trails were a testament to nature's artistry, and each stop along the way was a spectacle in itself. This loop was around 80 plus miles and shared multiple astonishing overlooks.
      Point Sublime Trail: A Serene Oasis
      Our second ride took us to the Point Sublime Trail, a hidden gem known for its majestic views. This trail, less traveled by many, allowed us to enjoy the tranquility of the wilderness, punctuated only by the awe-inspiring vistas. It was a place of pure serenity, where the silence enveloped us, offering a chance to embrace the peace and quiet while savoring the views. Along the way, a chance encounter with a coiled snake added a touch of excitement to the experience, reminding us of the untamed beauty of the natural world. This loop was also around 80 plus miles with some of the best overlooks the Grand Canyon has to offer. 
      Acknowledging Our Sponsors
      The success of the North Rim UTV Fun Run owes much to our dedicated sponsors, whose unwavering support ensures the continuation of these remarkable adventures. We extend our sincere thanks to Nash Powersports, Realty Providers, Rugged Radios, Shock Therapy, DRT Motorsports, Dirt Warriors Accessories, Kemi Moto, MRT Tires, McDermit Designs, Campfire Sports, Bob Moses Ceramic Coating, Gorilla Whips, Gorilla Offroad, Aftermarket Assassins, Rowley White RV, Memphis Audio, Factory UTV, Arizona Color Wraps, AJE Powersports, Macs Tie Downs, and a special acknowledgment to Shred 3D for their invaluable contribution as an event sponsor.
      A Date for Your Calendar
      For all adventure enthusiasts, make sure to mark your calendars and bookmark UTVOFFROADADVENTURES.com. Be prepared to sign up for your next off-road escapade, as these events unfold each month, promising thrilling experiences that will keep you coming back for more. If you seek further information about upcoming events, don't hesitate to reach out to [email protected]. We look forward to seeing you on our next adventure.
      The North Rim UTV Fun Run isn't just an event; it's an opportunity to immerse yourself in the awe-inspiring beauty of the Grand Canyon, share unforgettable moments with fellow adventurers, and create cherished memories that will last a lifetime. Don't miss out on this remarkable experience! This event is set for July 5-7, 2024. 

  • Gallery Images

Shop UTV batteries at ChromeBattery.com

  • Create New...