GL1800 driveshaft update and auxiliary fuel tank install

[Marc H]

This s a subject that comes up from time to time so I tried to take pics as I went so I could make a post about how to do it but life got in the way and here I am 3 months after I started so I'll do the best I can.

Obviously all the tupperware from the front shelter back has to come off.Getting to part of the bolts holding the subframe for the trunk gave me the most trouble.The body wasn't bad at all to remove.I took pictures as I went to help get things routed correctly on reassembly.



The shock get laid up on the frame out of the way.



Here you can see the mounting points to the frame.The bracket in the second pic is another but is removed to allow removal of the shock assembly.The angle piece is the front body mount.



After the brake calipers are removed from the brackets and the junction block unbolted and the bolts taken out of the mounts you are ready to roll the rear assembly away.Here you can see the original driveshaft and gearbox that will be removed.



The case bolts are removed and the case split so the bolt attaching the gear to the differential input shaft can be removed.

[Marc H]

Here you see the front half of the case and the gears inside.



And here is the complete gearbox.



The first pic is the front of the diff after the box is removed.The second is after a new seal is installed and the yoke that takes the place of the box installed.



The spud on the lower mount where the kit bolts to the frame has to be ground to allow the new driveshaft to slide past.

[Marc H]

I had a delay of several weeks here and got lazy about taking pics.If your adding the auxiliary fuel tank this is where you want to that.Take the fuel pump out and get all the gas out.Then using the template CSC provides drill a pilot hole in the fuel tank.You will need a knockout punch to make the correct sized hole.I found out there are a few different types of knockout punches.I had downloaded and read the install instructions before the kit came in so I could be prepared and have everything I needed.

I bought a set of knockout punches from Harbor Freight thinking I was good to go.The instructions emphasized measuring the punch and the fact the enlarged pilot hole I drilled to the size instructed wasn't big enough made me suspicious.When I measured correct sized punch was way too big.To the internet I go and find out the Harbor Frieght punches were conduit punches for punching holes in meter boxes and were sized by the size of conduit being used.Ordered the correct one and returned the others.

The inner fender is completely removed and the tank is installed.There is tab on the bracket that goes in a slot previously used by the fender the rear mount of the tank is P clamped to the frame rails.The hose connecting the 2 tanks is preassembled and installed using grommets.The grommets go in the tanks first and the hose barb swells them out to make a tight seal.



Due to my small work area I waited till I was finished reassembling the rear before I removed the top shelter and installed the vent line between the 2 tanks.

With work I had another delay and the pics stopped.My apologies but in short everything is reassembled at this point.I know I haven't hit every step but this is the highlights.

[David357]

Good thread, Marc.

Thank You!