Camel Tank Install Instructions Thank you for purchasing a Camel Tank for your F-Series BMW twin. TOOLS REQUIRED The average person can install Camel Tank in a couple of hours with basic tools. The total list of tools required to complete the installation will vary depending on which pannier rack system you are running (if any). On top of the tools you will need to remove your pannier racks (if required), you will need: Electric drill Step Bit or UniBit Pliers T25 Torx T40 Torx T45 Torx 4mm Allen key or socket 6mm Allen key or socket 3/8” Ratchet handle 1/2” Ratchet handle 10mm socket 24mm socket 13mm deep socket Short 3/8” extension 10mm combinat ion wrench 13mm combinat ion wrench 3/8” Torque wrench Flat metal file Spray lubricant Safety glasses Leather gloves Ut ility knife Side cutters Marker or small punch STEP 1: GAIN ACCESS a. Remove seat. b. Remove pannier racks if applicable. Remove factory grab bar if applicable. See Fig-1 c. Remove rear top cover. See Fig-1 d. Remove right side cover. See Fig-1 e. Unclip rear signal light clamps. See Fig-2a and 2b STEP 2: INSTALL REAR MOUNTING BRACKET SAFETY GLASSES & LEATHER GLOVES RECOMMENDED BMW alloy pannier equipped bikes: a. Remove M8 bolts holding the factory pannier crossbar. See Fig-X1 b. Slide Camel Tank rear locat ing bracket behind the factory cross bar and secure with supplied M8x25mm bolts and torque to 18ft/lbs. See Fig-X2 (The rectangular holes through the plast ic may need to be enlarged to clear both brackets) c. File square corners off the outer tab on factory cross-brace. See Fig-X3 Non-BMW pannier racks or no pannier racks: a. Cut perforated rectangles out using ut ility knife. A file may be required to clean edges after cutt ing. See Fig-3 a. Slide rear mount ing bracket up through the holes cut out in previous step. See Fig-4a b. Thread M8x25mm through bracket's holes and into threaded inserts in sub-frame cross member. See Fig-4b c. Tighten bolts to 18ft/lbs. Note: In 2012, BMW deleted the threaded inserts in the sub-frame cross member. This kit has been sent with M8x25mm allen head bolts and M8 Nyloc nuts. 2008-2011 bikes require the bolts to thread into the subframe inserts from the back. 2012 – current bikes will require the bolts to be inserted through the cross member from the front, then through the Camel Tank bracket (and BMW bracket if equipped) and secured with the Nyloc nuts. STEP 3: INSTALL FRONT BRACKET (CT-A & CT-B) CT-V2 Users See Supplemental Guide a. Inspect upper front sub-frame threaded inserts for dirt and debris, clean if necessary. See Fig-5 b. Slide M8 washers onto M8x35mm bolts then slide bolts through the mount ing holes on front mount ing bracket. Drop short spacers onto the bolts. See Fig-6a c. Thread bolts into sub-frame inserts. See Fig-6b d. Torque bolts to 18ft/lbs. STEP 4: DRILL BODYWORK SAFETY GLASSES STRONGLY RECOMMENDED a. Use scissors to cut drill template out. See Fig-7 b. Poke a small hole in the middle of each “X” on the template. c. Lay supplied template over inset area near right side rear signal lights. See Fig-8 d. Mark locat ion of fuel and vent line holes with felt marker or punch. e. Carefully drill a small hole with the step bit. Although there isn’t anything critical directly behind hole locat ions, take care not to run the drill bit any deeper than required to get through the body work. Do not drill anywhere but the spots shown on the template. f. Carefully enlarge the small holes to 9/16” (14mm) using the step bit. Again, be careful not to run the drill bit deeper than required. A small round file may be required to de-burr holes after drilling. STEP 5: INSTALL FUEL AND VENT LINES TO THE TANK (Tank not installed on bike yet) SAFETY GLASSES RECOMMENDED a. Install fuel cap to keep debris out of the tank while working with it. b. Attach short side of vent hose (vent hose has the T-connector) to the vent barb on the Camel Tank. See locat ion “B” in Fig-9 and Fig-9a. Please note, no hose clamps are required on vent line. c. Slide second fuel line onto the barb of the fuel suct ion straw (locat ion “A” on Fig-9) on the tank and secure with hose clamp. Note for CT-A and CT-B: If the provided hoses are the same length, cut one inch from one of the hoses. Hoses may need to be shortened depending on the bike. STEP 6: MOUNTING THE TANK a. Insert spacer into front through hole from the back side of the tank (the hole is tapered and smaller on the outside). See Fig-10 b. Slide the isolation bushing onto the rear-mount ing hanger. BMW pannier system: o Lubricate the cross-brace to get the bushing over the flat tab. The bushing is tapered so it is important to ensure the wider end is toward the bike. Slide over cross bar only unt il it clears the flattened portion of the cross-brace. o Slide the tank onto the bushing and hanger. You may need to wiggle the tank to get it past the lower lip of the front bracket. See Fig-11 o Push the tank onto the bushing and cont inue pushing unt il the tank contacts the locat ing bracket, then screw the M8 stud into the M8 insert in the tank. Secure with the supplied M8 Nyloc nut. Do not use the stud and nut to pull the tank toward the bracket. See Fig-X5 Non-BMW panniers: o Slide M16 flat washer onto hanger. o Spin M16 nut onto hanger threads. o Tighten M16 nut 2 full turns after it contacts the washer and bushing. All panniers: o Insert Allen head M8x45mm bolt and washer through the spacer and hole in the front bracket. You may have to wiggle the tank to get the bolt through the bracket hole. o Spin the M8 Nyloc nut onto the bolt. See Fig-12 o Torque to 18ft/lbs STEP 7: ATTACHING THE LINES a. b. c. d. e. f. Remove factory fuel tank vent line from barb (B) and cut zip t ie (A). See Fig-13a Care must be taken with the tank barb, as it is plast ic and can be damaged if too much force is applied. Slide the fuel suct ion hose through the forward drilled hole. Slide the screw style hose clamp over the fuel line. Slide hose and clamp over tank barb and secure clamp. See Fig-13b Slide hose from Camel Tank vent through the rear hole drilled in step 4 and attach to the factory fuel system vent line using the silver one way valve. Be aware that some bikes will be shipped from the factory with a black plast ic splice connector; if this is the case, use instead of silver one way valve. See Fig-14 g. Arrange hoses to ensure no kinks. h. Locat ion “A” and “D” should now connect to each other and locat ion “B” and “C” should connect. See Fig-9 Note: The vent line set-up and rout ing varies between bikes. Most non-US bikes will have a silver one-way valve and a black plast ic splice connector installed from the factory. Most US bikes will only have the black plast ic connector installed. This connector is found at locat ion “A” in Fig-13a on most US bikes and at the locat ion noted with the circle in Fig-14 on most non-US bikes. STEP 8: REASSEMBLE a. Reassemble covers and panels (varies with pannier systems) BMW panniers systems: Replace the M6 Torx bolt with supplied hex bolt on side rack. See Fig-X6 STEP 9: FILLING YOUR TANK a. ONLY FILL THE TANK WHILE THE BIKE IS ON ITS SIDE STAND. Filling while on the center stand will cause over-filling and may result in leakage of fuel from the vent line. b. Remove the gas cap and fill with gasoline unt il fluid level reaches the bottom of the gas cap threads. c. DO NOT OVERFILL. Over filling can lead to fuel leakage through the vent hose. d. Re-install fuel cap and t ighten unt il snug. DO NOT OVER-TIGHTEN. Thread damage may occur! STEP 10: GO ON YOUR NEXT ADVENTURE! a. Enjoy your ride and get home safely. b. Find us online! Share your photos and travel stories with other adventure riders on Facebook. Search for Camel ADV Products. DISCLAIMER Gasoline is dangerous as it is flammable and toxic. Inspect fuel tank, hose, fittings, fasteners and brackets for damage or wear before every use and after any upset, collision or other event likely to negatively affect the tank. Replace damaged components immediately. If you are unsure if the product’s condition is acceptable, consult a qualified professional. Camel ADV Products Ltd. will accept unused returns for 30 days from the date of purchase, subject to a 20% restocking fee. Purchaser must contact Camel ADV Products Ltd. via email at info@cameltank.com prior to returning product. Customer will be responsible for shipping, taxes and any customs fees/duties where applicable. Camel ADV Products Ltd warranties the Camel Tank against manufacturer defects for a period of 30 days. No warranty will be given for damage caused by incorrect install, physical contact or collision. Do not attempt to remove fuel suction tube or vent fitting from tank. These fittings have been sealed from the factory and attempting to remove them will cause damage to the tank causing fuel leakage. Damaged inserts in the tank are not covered by warranty. As regulations for fuel tanks varies vastly between different countries, it is up to the end user to ensure that the Camel Tank meets your local jurisdiction’s laws and requirements. If Camel Tank does not meet these requirements, do not install this product. In no event shall Camel ADV Products Ltd. be liable to the purchaser or user whether in contract, warranty, tort (including negligence or strict liability) or otherwise for any special, indirect, incidental, or consequent ial damages of any kind or nature whatsoever. Should any disputes arise, they shall be settled in a court of law located in the province of Alberta, Canada. Do you have an idea about how we can improve our product or service? Let us know by sending us an email at info@cameltank.com For installation instructions in English, French and Spanish or to view full color installation pictures, visit our website: www.camel-adv.com