Fuel Tank Fitment Instructions Tusk/Rally Raid Products/Seat Concepts kit Husqvarna 701 Enduro
Part #1849120001, 1849120002, 1849110001, 1849110002 Thank you for purchasing the Tusk/Rally Raid Products fuel tank/seat kit. This kit will allow you to install the Rally Raid Products KTM 690 Fuel tanks and shrouds to the Husqvarna 701 Enduro. When purchasing the Tusk Conversion Kit you should have also received these other products as well. 1. Rally Raid Products KTM 690 Fuel Tank Kit (white or natural) 2. Rally Raid Products KTM 690 Shrouds 3. Seat Concepts Seat (Standard or tall) These instructions will replace the Rally Raid Products instructions you will not need to use the instructions that are in the Rally Raid Products kit. Thoroughly read these instructions from start to finish before you begin. If you do not feel confident or have the necessary tools to complete this install it is recommended to take it to a qualified mechanic.
Fig.1 Fig.2 Fig.3 Fig.4 Fig.5 Fig.6 Fig.7 Fig.8 Fig.11 Fig.9 Fig.13 Fig.10 Fig.12
Instructions 1. Remove the seat and unplug the battery. Remove all of the side plastics from the bike. 2. Air box removal. Remove electrical plug from rear of air box. Undo the intake boot clamp (the one nearest the throttle body) and remove the four M6 screws from the air box. 2 front and 2 rear. 3. Lift up the rear of the air box and slide out. Once the air box is removed put clean tissues or cloth into the intake of injector assembly to prevent debris from entering the engine. 4. Follow the hose from the charcoal canister to the left side of the throttle body. Disconnect and install the supplied vacuum cap on the brass nipple, re-using the clamp to secure. 5. Take the vent hose from the fuel cap and disconnect from canister and vent to atmosphere, trim as required. Make sure the open end is in place where it will not get blocked with mud. Cutting at an angle can help prevent blocking. Air box plug Remove canister and bracket 6. Remove canister from bike. 7. Remove solenoid from bike. Unplug solenoid here
8. Jump the 2 pins on the plug that went into the solenoid with a 1000 Ohm 1/4 watt resistor. If you have dielectric grease, place in terminals before installing the resistor. 9. Tape up resistor plug with electrical tape to seal from water/dirt and zip tie in a secure location. 10. Undo both M6 screws and remove the rectifier from RH frame guard, keep the screws for later use. Remove both screws that hold the plastic shroud to the frame and discard the plastic cover and both screws. 11. Cut the cable ties that hold the rectifier wiring to frame and disconnect large brown connector plug on LH side of frame (may be very tight). Disconnect other connector to rectifier on RH side of frame and earth connector and remove rectifier and connected wiring loom from bike. Rectifier Install resistor here 12. Remove RH rear engine hanger lower torx screw and fit rectifier bracket special bolt Rally Raid Products (#31). Use Loctite when fitting back into frame. Remove rear horn bracket M6 screw then fit new rectifier bracket with M6 screws and Loctite securely. RRP #31 Special Bolt Horn bracket screw Remove plastic shroud
Horn bracket 13. Install Rally Raid Products rectifier bracket #28 re-using the two OEM bolts. M6 OEM bolts 14. Refit rectifier in place using both original screws then feed wiring through frame and reconnect both plugs as shown. Re-fit earth connector with screw on frame. Rectifier Bracket #28 15. Feed brown connector through gap between Y piece and plug in. Brown plug M6 Screws Rectifier
INSTALLATION INSTRUCTIONS AND INFORMATION 16. Upper Tank Mount Fitment. Locate Rally Raid Products tank mounts and hardware. #14,15, 41. Install tank mount as shown but do not tighten bolts, leave them loose enough that you can adjust the mount by hand. Make sure that the flat side of the tank mount is facing towards the rear of bike. Repeat for opposite side. Flat side facing rear 17. Lower Tank Mount Fitment. Locate the Rally Raid Products lower tank mount #13 and install in the location shown. Use Loctite on this bolt. Repeat for opposite side. Lower Tank Mount 18. Rubber Bumper installation. Remove the jnut that is in the frame tab and install the rubber bumpers. Item #7 in the Tusk Kit. Repeat step for opposite side. Install rubber bumper here Upper Tank Mount
19. Fuel Tank Fitment. From the Tusk Kit Locate items #1,2,5,6. Cap screws and spacers. Install the lower cap screw and spacer first and tighten finger tight. Place the spacer between the tank and the tank mount. Fig.2 M8 x 75mm Cap Fig.6 13mm Spacer Fig.5 6mm Spacer 20. Next install the upper cap screw and spacer, the upper tank mount will most likely need to be adjusted on the frame in order for the tank to line up with the mount. Adjust for optimal fit and tighten both cap screws. If you are satisfied with the fit, tighten the three screws on the tank mount. Remove tanks for now. Repeats steps for opposite side. Fig.1 M8 x 70mm Cap Screw
21. Fuel Tank Adapter Install. Empty as much fuel as you can from the OEM tank before starting. Remove rear wheel and rear mud flap in order to access fuel pump. Remove mud flap screws 22. Remove the four M5 screws that connect the fuel pump housing to the bottom of the tank. (fuel may leak out as housing is lowered). Release clips here 23. Gently lower pump assembly and unclip black housing from pump by releasing both clips on each side of pump. Fuel pump housing Housing Cap Fuel pump
24. Using a 5/16 drill bit, drill a hole in the bottom of the housing centering it the best you can. It does not need to be exact and does not need to line up with anything. Make sure all of the plastic is cleaned up and removed from the housing to avoid any unwanted debris from entering the fuel system. Re-install the housing onto the fuel pump and make sure the housing securely clips into the black housing cap. Drill 5/16 Hole 25. The Rally Raid Products adapter and banjo fitting will not be used. Rally Raid adapter and banjo fitting 26. Locate the supplied Tusk Adapter Plate and the Rally Raid Products O-ring. With the O- ring in place on the adapter plate, install to the bottom of the fuel pump housing using the (4) M5 x.8 x 30mm hex bolts and the (4) M5 flat washers supplied in the Tusk Kit. The 90 degree brass elbow should be pointing towards the right hand side of the bike. Make sure you tighten in a cross pattern so that the housing will seat and seal correctly to the tank. Tighten bolts. Tusk Adapter Plate Rally Raid O-ring 90 deg NPT elbow pointing right M5 bolts and washers (4)
27. Locate the fuel line assembly supplied in the Rally Raid Products kit. Study the fuel line diagram in the image to the right. To rear OEM tank To LH tank To RH tank Note: It is vitally important that the fuel line to the left tank is installed correctly. Improper placement could cause contact with header pipe and a potential fire hazard. Rally Raid quick disconnect 28. Route the fuel line as shown and use the supplied zip ties to secure the fuel lines to the desired location. To RH tank Note: Extra Tusk Fuel line is supplied if the Rally Raid Products fuel line runs short. 29. Reinstall both tanks. When refitting both tanks pass the fuel lines through the plastic P clips on the inside of the tank. Use the fuel line clamps supplied in the Rally Raid Products Kit. Trim the fuel line for optimal fit. Reinstall all tank hardware and tighten. To LH tank P Clip
30. Reduced crankcase breather tank. Install the Rally Raid Products Reduced crankcase breather tank as shown in the image to the right. Reduced Crank Case Breather Cut notch here 31. It is required to cut a small notch in the plastic clamp that holds the tank to the frame. Plug in all the hoses in the same fashion as the OEM crank case breather tank. 32. Next you will reinstall air box assembly, when installing the boot to the throttle body be sure that it fits correctly. It is critical that there are no leaks around the boot.
33. Trimming of right hand side plastic. You will need to trim a notch in the right hand side plastic to allow for fuel line clearance. This can easily be done with a body saw, jig saw or small grinder. After cutting be sure to file or sand the edge smooth. 34. Reinstall all plastics onto the bike. Right hand side plastic Cut notch here 35. Install your new Seat Concepts Seat, it will install same as the OEM seat. 36. This concludes the installation of the Rally Raid Products Fuel Tank and Seat kit for the Husky 701 Enduro.
PROCEDURE FOR FILLING TANKS It is advisable when filling both front tanks and rear OEM tank to isolate the front tanks by turning both fuel taps to the off position. This helps prevent siphoning between the tanks as they are being filled. Since the front tanks are mounted higher that the rear tank, fuel will flow out the rear tank over flow when all tanks are full. You must use the fuel in the rear tank before opening the front tanks. LOW FUEL WARNING Due to the extra fuel in the front tanks, the range increases when the low fuel warning light signals. With the front tanks fitted the range from the signal to empty is around 25 km to 60 km, depending on the riding conditions. QUICK DISCONNECTORS Before removing front tanks, you must disconnect the black quick connector by pushing in the stainless tag and gently pulling apart. This is to prevent fuel discharge from the rear tank through the fuel lines. Whilst disconnected we strongly recommend to cover the ends of the quick connectors with a clean plastic bag, latex glove or similar, this prevents debris from entering the connector. Before reconnecting, push in the stainless steel lever and push both halves together taking care. Once connected check for leaks, if the connector is leaking, disconnect again and thoroughly clean O-ring and plunger then reconnect. Refit OEM radiator guard with both special stepped M6 screws into radiator. DO NOT USE LOCTITE OR OVERTIGHTEN Re-connect battery positive terminal and refit red insulating cover.
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