INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

Fuel Tank Fitment Instructions

Tusk/Rally Raid Products/Seat Concepts kit

Husqvarna 701 Enduro

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

Part #1849120001, 1849120002, 1849110001, 1849110002

Thank you for purchasing the Tusk/Rally Raid Products fuel tank/seat kit. This kit will allow you

to install the Rally Raid Products KTM 690 Fuel tanks and shrouds to the Husqvarna 701 Enduro.

When purchasing the Tusk Conversion Kit you should have also received these other products as well.

1. Rally Raid Products KTM 690 Fuel Tank Kit (white or natural)

2. Rally Raid Products KTM 690 Shrouds

3. Seat Concepts Seat (Standard or tall)

These instructions will replace the Rally Raid Products instructions you will not need to use

the instructions that are in the Rally Raid Products kit. Thoroughly read these instructions from

start to finish before you begin. If you do not feel confident or have the necessary tools to complete

this install it is recommended to take it to a qualified mechanic.

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

Fig.3 Fig.4

Fig.7

Fig.9

Fig.11

Fig.6 Fig.5

Fig.2 Fig.1

Fig.8

Fig.10 Fig.12

Fig.13

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

1. Remove the seat and unplug the bat-

tery. Remove all of the side plastics

from the bike.

2. Air box removal. Remove electrical

plug from rear of air box. Undo the

intake boot clamp (the one nearest

the throttle body) and remove the four

M6 screws from the air box. 2 front

and 2 rear.

3. Lift up the rear of the air box and slide

out. Once the air box is removed put

clean tissues or cloth into the intake of

injector assembly to prevent debris

from entering the engine.

4. Follow the hose from the charcoal can-

ister to the left side of the throttle

body. Disconnect and install the sup-

plied vacuum cap on the brass nipple,

re-using the clamp to secure.

5. Take the vent hose from the fuel cap

and disconnect from canister and vent

to atmosphere, trim as required.

Make sure the open end is in place

where it will not get blocked with mud.

Cutting at an angle can help prevent

blocking.

6. Remove canister from bike.

7. Remove solenoid from bike.

Instructions

Remove canister and bracket

Air box plug

Unplug solenoid here

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

8. Jump the 2 pins on the plug that went into the

solenoid with a 1000 Ohm 1/4 watt resistor.

If you have dielectric grease, place in termi-

nals before installing the resistor.

9. Tape up resistor plug with electrical tape to

seal from water/dirt and zip tie in a secure lo-

cation.

10. Undo both M6 screws and remove the rectifier

from RH frame guard, keep the screws for lat-

er use. Remove both screws that hold the

plastic shroud to the frame and discard the

plastic cover and both screws.

11. Cut the cable ties that hold the rectifier wiring

to frame and disconnect large brown connect-

or plug on LH side of frame (may be very

tight). Disconnect other connector to rectifier

on RH side of frame and earth connector and

remove rectifier and connected wiring loom

from bike.

12. Remove RH rear engine hanger lower torx

screw and fit rectifier bracket special bolt Rally

Raid Products (#31). Use Loctite when fitting

back into frame. Remove rear horn bracket

M6 screw then fit new rectifier bracket with M6

screws and Loctite securely.

RRP #31 Special Bolt

Horn bracket screw

Remove plastic shroud

Rectifier

Install resistor here

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

13. Install Rally Raid Products rectifier bracket

#28 re-using the two OEM bolts.

14. Refit rectifier in place using both original

screws then feed wiring through frame and

reconnect both plugs as shown. Re-fit earth

connector with screw on frame.

15. Feed brown connector through gap between Y

piece and plug in.

Rectifier Bracket #28

M6 OEM bolts

Horn bracket

Brown plug M6 Screws

Rectifier

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

16. Upper Tank Mount Fitment. Locate Rally

Raid Products tank mounts and hardware.

#14,15, 41. Install tank mount as shown

but do not tighten bolts, leave them loose

enough that you can adjust the mount by

hand. Make sure that the flat side of the

tank mount is facing towards the rear of

bike. Repeat for opposite side.

17. Lower Tank Mount Fitment. Locate the Rally

Raid Products lower tank mount #13 and

install in the location shown. Use Loctite on

this bolt. Repeat for opposite side.

18. Rubber Bumper installation. Remove the j-

nut that is in the frame tab and install the

rubber bumpers. Item #7 in the Tusk Kit.

Repeat step for opposite side.

Install rubber bumper here

Lower Tank Mount

Upper Tank Mount Flat side facing rear

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

19. Fuel Tank Fitment. From the Tusk Kit Lo-

cate items #1,2,5,6. Cap screws and spac-

ers. Install the lower cap screw and spacer

first and tighten finger tight. Place the spac-

er between the tank and the tank mount.

20. Next install the upper cap screw and spacer,

the upper tank mount will most likely need to

be adjusted on the frame in order for the

tank to line up with the mount. Adjust for

optimal fit and tighten both cap screws. If

you are satisfied with the fit, tighten the

three screws on the tank mount. Remove

tanks for now. Repeats steps for opposite

side.

Fig.6 13mm Spacer

Fig.5 6mm Spacer

Fig.2 M8 x 75mm Cap

Fig.1 M8 x 70mm Cap Screw

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

21. Fuel Tank Adapter Install. Empty as much fuel

as you can from the OEM tank before starting.

Remove rear wheel and rear mud flap in order

to access fuel pump.

22. Remove the four M5 screws that connect the

fuel pump housing to the bottom of the tank.

(fuel may leak out as housing is lowered).

23. Gently lower pump assembly and unclip black

housing from pump by releasing both clips on

each side of pump.

Release clips here

Fuel pump housing

Fuel pump

Housing Cap

Remove mud flap screws

Drill 5/16” Hole

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

24. Using a 5/16” drill bit, drill a hole in the bot-

tom of the housing centering it the best you

can. It does not need to be exact and does

not need to line up with anything. Make sure

all of the plastic is cleaned up and removed

from the housing to avoid any unwanted de-

bris from entering the fuel system. Re-install

the housing onto the fuel pump and make

sure the housing securely clips into the

black housing cap.

25. The Rally Raid Products adapter and banjo fit-

ting will not be used.

26. Locate the supplied Tusk Adapter Plate and

the Rally Raid Products O-ring. With the O-

ring in place on the adapter plate, install to

the bottom of the fuel pump housing using the

(4) M5 x .8 x 30mm hex bolts and the (4) M5

flat washers supplied in the Tusk Kit. The 90

degree brass elbow should be pointing to-

wards the right hand side of the bike. Make

sure you tighten in a cross pattern so that the

housing will seat and seal correctly to the

tank. Tighten bolts.

Rally Raid adapter and banjo fitting

Tusk Adapter Plate

Rally Raid O-ring

90 deg NPT elbow pointing right

M5 bolts and washers (4)

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

27. Locate the fuel line assembly supplied in the

Rally Raid Products kit. Study the fuel line

diagram in the image to the right.

Note: It is vitally important that the fuel line to the

left tank is installed correctly. Improper placement

could cause contact with header pipe and a poten-

tial fire hazard.

28. Route the fuel line as shown and use the sup-

plied zip ties to secure the fuel lines to the de-

sired location.

Note: Extra Tusk Fuel line is supplied if the Rally

Raid Products fuel line runs short.

29. Reinstall both tanks. When refitting both tanks

pass the fuel lines through the plastic P clips on

the inside of the tank. Use the fuel line clamps

supplied in the Rally Raid Products Kit. Trim

the fuel line for optimal fit. Reinstall all tank

hardware and tighten.

Rally Raid quick disconnect

To rear OEM tank

To LH tank

To RH tank

P Clip

To RH tank

To LH tank

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

30. Reduced crankcase breather tank. Install the

Rally Raid Products Reduced crankcase

breather tank as shown in the image to the

right.

31. It is required to cut a small notch in the plastic

clamp that holds the tank to the frame. Plug

in all the hoses in the same fashion as the

OEM crank case breather tank.

32. Next you will reinstall air box assembly, when

installing the boot to the throttle body be sure

that it fits correctly. It is critical that there are

no leaks around the boot.

Reduced Crank Case Breather

Cut notch here

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

33. Trimming of right hand side plastic. You will need to trim a notch in the right hand side plastic to

allow for fuel line clearance. This can easily be done with a body saw, jig saw or small grinder. Af-

ter cutting be sure to file or sand the edge smooth.

34. Reinstall all plastics onto the bike.

Cut notch here

Right hand side plastic

35. Install your new Seat Concepts Seat, it will install same as the OEM seat.

36. This concludes the installation of the Rally Raid Products Fuel Tank and Seat kit for the Husky 701

Enduro.

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

PROCEDURE FOR FILLING TANKS

It is advisable when filling both front tanks and rear OEM tank to isolate the front tanks by turning both

fuel taps to the off position. This helps prevent siphoning between the tanks as they are being filled.

Since the front tanks are mounted higher that the rear tank, fuel will flow out the rear tank over flow

when all tanks are full. You must use the fuel in the rear tank before opening the front tanks.

LOW FUEL WARNING

Due to the extra fuel in the front tanks, the range increases when the low fuel warning light signals.

With the front tanks fitted the range from the signal to empty is around 25 km to 60 km, depending on

the riding conditions.

QUICK DISCONNECTORS

Before removing front tanks, you must disconnect the black quick connector by pushing in the stainless

tag and gently pulling apart. This is to prevent fuel discharge from the rear tank through the fuel

lines. Whilst disconnected we strongly recommend to cover the ends of the quick connectors

with a clean plastic bag, latex glove or similar, this prevents debris from entering the connector.

Before reconnecting, push in the stainless steel lever and push both halves together taking care. Once

connected check for leaks, if the connector is leaking, disconnect again and thoroughly clean O-ring

and plunger then reconnect.

Refit OEM radiator guard with both special stepped M6 screws into radiator.

DO NOT USE LOCTITE OR OVERTIGHTEN

Re-connect battery positive terminal and refit red insulating cover.

INSTALLATIO

N I

NSTRU

CTIO

NS A

ND

IN

FO

RM

ATIO

N

Decal Installation Instructions