Fitting auxiliary fuel tank to the CRF250 Rally

The standard Honda CRF250 Rally has a 10.2L tank which gives a range in the region of 200 miles, depending how you ride. For our trip we need to be able to cover 300 miles without needing to refuel and so we need to carry at least another 5L of fuel.

Fortunately there are a number of solutions to this problem, some more expensive than others.

We investigated replacing the tank with a larger unit to give us the extra capacity however, the cost was prohibitive.

After much searching we settled on an inexpensive solution available on Amazon. A simple 5L mountable fuel tank that is a copy of the extremely expensive Rotopax system.

The tank itself is pretty solid, in fact it’s strong enough to stand on. The two U bolts that it comes with don’t really lend themselves to mounting on a flat plate and so I replaced these with ordinary bolts with nylock nuts.

Using electrical tape to hold the mount into the centre of the rack plate I used a centre punch to mark the spot for each hole to be drilled. Using a good quality drill bit I drilled the four mounting holes in the aluminium plate and mounted the tank bracket using four short bolts with washers and nylock nuts. Once tight, I mounted the rack plate on the bike and fitted the tank.

As you can see in the photos it’s a nice addition to the bike and isn’t too big or intrusive. Importantly it leaves plenty of room for my dry bag to sit across the back of the seat to carry the camping gear.

Total cost of this little project was £25.08 and about 40mins of my time.

Next project is new handle bars and bar risers, stay tuned!