Fuel tank rubbing wire harness and wires

thebirdman · Dec 2, 2011

Hey guys, I've been trying to search and haven't came up with what I'm looking for? I'm just finishing up some maintance on my 06 700 and am trying to come up with a cure for the wires that rub the front of the fuel tank. Do any of you mount the voltage regulator forward or in a different location? Do you just tape up all the wires or place foam or something over them to prevent the tank from rubbing through them? It seems like i remember a thread about this but can't seem to find anything! Any info would be great, thanks!

Newfusion900 · Dec 2, 2011

I have heard that some move the tank about 1" back. Don't know how everything mounts back up but as I said I just have heard that it can be done and have not done it myself.

TrailRebel · Dec 2, 2011

You can drill a hole about 3/4 to 1" forward in the chassis for the lower hole on the voltage regulator...it should get the wiring far enough out of the way.

thebirdman · Dec 2, 2011

TrailRebel said:
You can drill a hole about 3/4 to 1" forward in the chassis for the lower hole on the voltage regulator...it should get the wiring far enough out of the way.

So do you just drill a new lower hole and just not put a bolt in the upper hole of the regulator? I already thought about doing that but didn't know if i needed both bolts holding the regulator in place?

miko700 · Dec 2, 2011

I also moved my voltage regulator up....i just moved both holes......you only need about 3/4 of an inch is plenty and it works great...

TrailRebel · Dec 3, 2011

Here's a picture of what I did. I forgot to get a picture from the backside, but when doing this, you can only go so far because the regulator will hit the bracket for the ECU. Loosen the top bolt on the VR, remove the lower bolt, and just try to 'straighten' the VR, and you'll see exactly what I'm talking about.

guidoxpress · Dec 3, 2011

TrailRebel said:
Here's a picture of what I did. I forgot to get a picture from the backside, but when doing this, you can only go so far because the regulator will hit the bracket for the ECU. Loosen the top bolt on the VR, remove the lower bolt, and just try to 'straighten' the VR, and you'll see exactly what I'm talking about.

bingo, did this 3 seasons ago on both my 06s (700 and 900) and rubbing was never an issue since.

TrailRebel · Dec 3, 2011

guidoxpress said:
bingo, did this 3 seasons ago on both my 06s (700 and 900) and rubbing was never an issue since.

Thanks, guido! I did this after I saw one of your build threads! You rock, man!

thebirdman · Dec 3, 2011

Alright thanks guys for all the info and picture! I'll go get a new hole drilled and forget about them rubbing!

05900 · Dec 3, 2011

make sure to protect wiring as long as you have it torn down that convoluted tubing is cheap.

Danbot · Dec 4, 2011

I moved my fuel tank back aprox 1" Everything fits properly still and there is no contact between the tank, vr, or any wiring in that area anymore.

danduvall · Dec 4, 2011

Danbot said:
I moved my fuel tank back aprox 1" Everything fits properly still and there is no contact between the tank, vr, or any wiring in that area anymore.

what did you do?? just move all the bolt holes in the tunnel back 1"??

the vr in my 06 900 is all the way up againts my jackshaft bearing, and the top bolt cant be moved up any more! (factory positioning)... and i need to move i to keep the wires from rubbing?!?!?

05 tmk 900 · Feb 28, 2012

I took a square file and filed the slots for the gas tank back 1/2 inch, totally released the pressure on the wires in front of the tank. I also slotted the plastic on the tool box so the seat latch is still tight.
I squirted some expanding foam between the tank and wires to keep them in place and to see tightness issues in the future....

Newfusion900 · Feb 28, 2012

05 tmk 900 said:
I took a square file and filed the slots for the gas tank back 1/2 inch, totally released the pressure on the wires in front of the tank. I also slotted the plastic on the tool box so the seat latch is still tight.
I squirted some expanding foam between the tank and wires to keep them in place and to see tightness issues in the future....

Expanding Foam??? Sounds like that would be a mess to work on if you ever have to get in around the ecu.

900Spartan · Mar 9, 2012

05 tmk 900 said:
I took a square file and filed the slots for the gas tank back 1/2 inch, totally released the pressure on the wires in front of the tank. I also slotted the plastic on the tool box so the seat latch is still tight.
I squirted some expanding foam between the tank and wires to keep them in place and to see tightness issues in the future....

Got pics of the tank move or foam job?

heavy d · Mar 11, 2012

Just went through this very thing with my '05 900 RMK. Decided the easiest fix was to move the fuel tank back about 3/4". There was plenty of meat on the factory mountin tabs to drill new holes and it did not affect the fit of the rest of the components what-so-ever.

TrailRebel · Mar 10, 2013

TTT

Either one of these mods will keep you from being stranded on the hill or in the woods!!!!

CHAFE PROTECTION!!!!!!!!!

:cheer2:

Fuel tank rubbing wire harness and wires

thebirdman

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Newfusion900

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TrailRebel

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thebirdman

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miko700

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TrailRebel

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guidoxpress

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thebirdman

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05900

Embrace the BRAAAAAAP!

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05 tmk 900

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900Spartan

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