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Get more mileage out of your desert tank by blowing it up… No, not literally! Take a clean, empty tank, shut the petcock, and fill it full of steaming-hot water (not boiling water, though—that's too hot). Once you have the tank full, carefully replace the cap. Pressurize the tank with an air nozzle through the breather hole in the cap. Be careful to stay clear of the breather vent, as very hot water could blow back out and you risk burning yourself! The pressure and heated water will slightly stretch and expand the tank. Believe it or not, you can usually gain one to two quarts of extra capacity by doing this. Think we're crazy? Well, watch the water level drop to measure your success. When you are done, let the water cool and then dump it out. Be sure to dry out all water residue before filling it up with fuel.
 

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So the tank is bolted to the bike. What sort of pressure range are you guys pumping into the tanks and how long do you hold the tank under pressure for. Sounds like a good idea, more fuel is always handy to have

cheers
 

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So the tank is bolted to the bike. What sort of pressure range are you guys pumping into the tanks and how long do you hold the tank under pressure for. Sounds like a good idea, more fuel is always handy to have

cheers

Yes bolt the tanbk to the bike if you dont the tank bolt tabs or whatever may shift on you. THe pressure range is measured with a very sophisticated tool called an EB MK I (eye ball model 1). I did mine gradually. Nothing says you cant stretch it more than once. Ive also heard of people using a valve stem and some metal tubbing to make an additional one way valve to the overflow tube of the gas cap.

How much is enough fuel. Is 4 gallons (IMS tank) gonna get you 50-60 miles on a stock 525? Any idea if a 540 will get 50 miles out of 4 gals?

Teixeira's 576cc had a IMS 4 gal that had been expanded to about 4.75 gals. It got him 65-70 (IIRR) miles before he started to worry. A dez built TRX450R will get about 70 on a 3.8 tank.
 

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Nice one, I will definitley be giving that a go. With my old ims I used to get about 100 to 110 km out of it doing desert races pretty much pinned all the time.

Cheers
 
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