Longer range for the SV1000

More modern than I usually post, but my main bike these days is a 2003 Suzuki SV1000. Its a great motorcycle, but the 12.5 litre gas tank means a limited range of 200ish kilometers before getting into reserve. Not near enough for touring- and most of my highway riding is a 300 km "commute" and I've put 16.2 litres of gas into the tank while filling up, that's a pop can of gas left- too close.

  I decided that the best way to add fuel capacity was to take up some of the under tank airbox space. Removing the airbox lid and sticking a piece of 2" Styrofoam to the underside of the tank to reduce airbox size saw no change in performance, so I poured in a measured 3 litres of water and marked it. A cardboard template was made and the size transferred to a piece of sheetmetal. Wish I could say I welded it in- but reliably welding 24 gauge sheet metal is not within my capabilities. (Thanks, Fred!)

 The plastic airbox lid was trimmed down, letting the underside of the tank act as a lid. The snorkel is retained for sound suppression. Some weatherstrip tape sealed the whole area.

 Results are great. The bike looks the same but now has 3.5 litres of extra fuel - more than enough for my riding style and with only a bit more low speed intake honk.

 

Hard to believe the SV carries more fuel than the Katana.