This is one of the cheapest and most effective mods I have ever done to my XT660Z, even though XT’s tank big enough to visit 10 Starbucks coffee shops without a refuel – on a long trips or tours – there is always a need for a bigger fuel tank, and this mod – does just that!

When fueling up, it looks like Teneres tank will fill up to the top, but since the filler neck is so low, there is always going to be a massive air pocket. That air pocket is not vented and could easily fit another Liter of fuel! How cool and silly is that at the same time!

So here is the idea – to make a small hole to help air to escape and let the fuel take its place and for this mod we will need only two things :

Size 4 Allen key to undo 4 bolts to remove the fuel cap (only 3 bolts on the outer ring and 1 under the cap), and
5-8mm drill bit and Hand operated drill or something similar (i used step-drill bit and a screwdriver to turn it by hand)

I strongly advise not to use electric drill as fuel fumes, air and sparks do not go well together in an uncontrolled environment. So stay away from those for your own safety.

What I do advise – get some paper towel, roll it in a way that it shapes like a small bowl and plug the filler hole with it – that way all the shaving will come out with the paper towel, and none of it will fall inside of the tank. But if you drop some – that is fine – fuel filter inside of the tank wont let it go far anyway.

Making the hole itself is easy as plastic is as soft as butter. For that I used a strepper drill bit mounted on the screw driver- steps on the drill bit also ensured that I will not go too deep in and out though the other end too!

The best place to make a vent – just under the metal ring – inside of the cutout for the locking mechanism!

Once done, I would suggest to spray some wd-40 or something similar down the drain hole on the right side, just in case it got clogged up with dirt over the time, but be sure to catch all liquid on the other side of the pipe (other end is near the brake pedal).

And that’s about it, easy mod, costs nothing, and one day that extra fuel might just save you from being stranded (or pushing your bike to the garage)!