1G AWD full blown dual intank install

[Bryan 93]

Was installing a dual intank full blown setup today on my 1g awd. No install instructions or anything with it, and i can't find any pics of a 1g install. The only way I could see to be able to fit the level sender and both pumps in was to locate the level sender and pump inlet filters on the same side. This is a little weird because the fuel line from the pumps to the cnc'd cover are not a straight shot, the bend looks odd. If I installed the pumps so the fuel lines were straight I can't imagine getting the pumps and level sender into the tank. Can anyone confirm this is the right way?

 

[airmail96]

How you have it is perfectly fine, thats the way mine looks in the tank.

 

[Bryan 93]

Cool! I figured it was fine, but am I kind of annoyed it lacked any instructions. Did you by any chance do anything about the lack of ground connection for the sensors (fuel level and low fuel)? The stock unit has a ground wire for the unit going to the cover. The sensors all attach to the cover so I assume the ground connection is made this way on the stock unit because they are both single wire sensors. This unit is anodized, so I doubt the sensors make very good electrical contact, and nothing specifically grounds the CNC'd portion so I would think electrically they would be floating. I am a bit concerned about the sensors working properly. I was thinking of drilling and tapping a hole through the plate, running a bolt through it, and using a wire to the sensor bracket inside the tank and a wire to a good chassis ground on the outside.[DOUBLEPOST=1414508998][/DOUBLEPOST]I did some measurements last night and I am definitely going to run a separate chassis ground to the hanger, just like the stock unit. The case of the pumps are not grounded, and even if they were the anodized hanger probably wouldn't make good electrical contact, so the only ground would be achieved from bolting the hanger to the tank (again through an anodized coating), and the tank to the chassis. My fuel tank has been completely renu'd with a nice thick coat of paint over everything, including where it mounts to the chassis.

 

[mercaholik]

And aluminum is not a good conductor, so good call. I doubt it would have worked anodized or not but def worse with it.

 

[Yamahaulin]

I have one for the 2g and i'll give you a word of advice go to your local motorcycle dealer and buy a tube of yamabond and put on the wires where it passes through the aluminum on both sides, otherwise you'll be smelling fuel fumes after a while as whatever they use at full blown tends to deteriorate after time.

 

[Bryan 93]

I think the 1G design is actually a bit better than the 2G with this respect. The wires pass through the thick part of the hanger, the amount of RTV they use to fill this cavity must be pretty significant, much more than the 2G version, where the wires only pass through the thin section. But thanks for the info.

 

[airmail96]

Honestly I never did do anything for the ground, but I never had any issue with the sender when I had it in the car running a single pump. Everything worked as it should, but i think you are onto something by running a seperate ground.

 

[Paul@RTM]

No doubt about it, depending on the type of anodizing used, the anodizing CAN act as an insulator to electrical current. We at RTM got our own sending units anodized and the anodizer advised us to plug any threaded holes that we intended to use as a ground so that they wouldn't be anodized. We did so and we tested our units and sure enough: raw aluminum = good conductor, anodized aluminum = bad conductor. I can't speak for ALL forms of anodizing, but it's certainly true for some forms.

 

[1killerEVO]

Hey paul@RTM you guys should make one for the 2g

 

[Bryan 93]

I did end up drilling and tapping an m4x0.7 hole in the top. I then ran a small wire to the bolt that mounts the sensors to the hanger. I measured with a DMM after and everything looks good. I was very close to ordering the RTM dual pump hanger, I ended up with the full blown version basically because I wanted an upgraded return line. I didn't want to adapt to the stock return location on the tank, just didn't seem as clean an install. Wouldn't have been the biggest deal, but my logic none the less.