rcdodge77,
How much further will you be able to ride between Gas stations, compared to a stock volume of gas?

I believe i will be able to go 200 miles before the light comes on(Or close to it anyway).  After i punched the holes in the filler neck i could get another quart of fuel in, and that will get me 165-170 miles before the light comes on.  This should get me another 30 miles.  I hope to have everything completed shortly after christmas, but the weather probably won't let me test it out too much!!!

I like this idea. I hate to be the one rider that screws up a groups fuel stops on a long ride.
Couple a ?? if i might?
Will you be able to transfer fuel while under way? In case of a tip over or some other mishap will the fuel stay where its sposda be? I know the oem fuel pump will shut off at a set pressure or if the engine should stop or if the inclinometer registers a severe angle.

Tim, i am like you.  I hate being the one rider that screws up the fuel stops.  The fuel tank is the only thing i dislike about the Stratoliner. 
I will be able to transfer the fuel while riding.  I am hooking a switch up to the pump and installing it in my fairing.  My hope is that once this is all hooked up, i can test it out and find out how long it takes to transfer the fuel to the main tank, and then when i get to about 1/2 tank then i can flip the switch and transfer the fuel.  I am hopeful that i can hear the pump run, or feel when the fuel line starts sucking air so i know when to shut the pump off.  If i can't hear it or feel the line, then i will time how long it takes to transfer the fuel and just run the pump for a set amount of time.  I am also installing either a shut off valve, or a check valve in the transfer line so the fuel won't go from the main tank to the external tank.  I don't know about it leaking fuel in a rollover though.  When i fill the external tank up, i will remove it and turn it over and see how much it leaks.  Lets just hope i can keep the bike upright!!

OK RC when are you testing this?  We need you to get out there today and run some tests!  ASAP brother!
I love where you are headed with this one.  Can't wait for your real world results.

Yea Bob let us know and by the way if you need roll over tester I gave that up.

Hmmm, if the Aux. tank is not vented, won't the extra pump to transfer fuel cause the  tank to collapse?  Will the use of the extra pump cause excessive fuel to the secondary tank under the seat?

How is fuel normally transferred from tank to secondary tank?  I have no idea as to how this 2 tank system works, other than the fuel pump is in the tank under the seat.  Is the PSI of this pumps main purpose to deliver fuel to the injectors or to pull fuel from tank, or both?
 

I have seen on line people who put their tour tank in their trunks so if they seal right it must not be too bad. I would think you would have to vent it with a hoes out the bottom of the bag. So if you didn't over fill or spill any gas it may not be an issue.

Hmmm, if the Aux. tank is not vented, won't the extra pump to transfer fuel cause the  tank to collapse?  Will the use of the extra pump cause excessive fuel to the secondary tank under the seat?

How is fuel normally transferred from tank to secondary tank?  I have no idea as to how this 2 tank system works, other than the fuel pump is in the tank under the seat.  Is the PSI of this pumps main purpose to deliver fuel to the injectors or to pull fuel from tank, or both?
 

The auxilary tank is vented.  I was just checking it and the cap appears to seal very tight, but it still slowly vents when you try to suck air thru the outlet.The transfer pump i decided to use is only 4-6 psi, so there shouldn't be excessive fuel in the secondary tank.  I think, from looking at the drawings, it appears that fuel is gravity fed from the main tank to the secondary tank.  There are 3 lines on the top of the fuel pump assembly.  2 of them are feed lines from the main tank.  One of them is the main pressure line that goes from the fuel pump to the fuel injector rail.  There is also a small line on the side of the external fuel tank.  This line is coming from the fuel pressure regulator on the left side of the engine and is the return line.  Dgunner has a similar setup and he uses a t fitting into the fuel line on the left side of the main tank that goes into the secondary tank.  I will connect the same way.  The only difference is that his is gravity fed, and mine will be pumped.

I've been thinking about this one.  Knowing what you do for a living I'm probably just asking stupid questions but.

The tank will have to be vented through the cap.  The saddle bag is gonna smell like fuel something awful I would think. How are you gonna control that?

It would seem to be easier to pump the fuel to the bikes fuel system, instead of the main tank. However this would require some type of filtration system.

Check out Tour Tanks www.tourtanks.com. They make a line of stuff to do just what your looking to do. I have one of their 2 gallon touring tanks, though it's just storage and not connected to the bike. Very well made!

Grumpy, i am optimistic that i won't get any fuel smell since the fuel cap is sealed very tight.  This was a concern of mine when i first started this project, and it still might be a problem.  Only time will tell.  It would be possible to pump fuel directly to the bikes fuel system, but it would be much more complex and WAY more expensive!!  I hope to have this entire project done for only about $110.    I have checked out tourtanks.com.  They do not have quite as good of prices or as big of a selection as coyote-gear.  Coyote Gear also has a very big Ebay store with very good prices.  I was able to get this tank for only $73 including shipping. 

Bob l would think if you have a screw or a tight sealing cap you shouldn't  have
Any leakage. I would do a shut off valve vs a check valve, I have had them fail on me.
Turn pump on then open the valve and reverse  when empty.

Thanks for the tip Dave!!!  I will use a shut off valve instead of a check valve.  That would cause big problems if the check valve failed.  I was hoping for the convenience of not having to mess with a valve, but i don't want any problems either!!!!

Just a quick update..... I have all the plumbing installed and the tank sitting in the saddle bag.  The installation turned out very clean and i was real happy with the routing of the fuel line and shut off valve.  The fuel line exits near the rear of the saddle bag and runs between the bag and the fender.  The shut off valve is on the right side between the frame and the saddle bag.  It is hidden very well, but is easily accessible while riding.  I really wanted the shut off valve on the left side, but to keep the installation clean i decided to put it on the right side.  It will make it a little challenging to open the valve while riding, but my throttle lock will help out with that!!!  I temporarily hooked up the fuel pump and filled up the auxiliary tank, and everything worked perfectly and transferred the 3/4 gallon of fuel to the main fuel tank in about a minute and a half.  Tomorrow i will take apart the fairing and mount the switch for the pump in the fairing and hook up the wiring.  Hopefully tomorrow i can get a road test in!!!   I will post some pictures when complete.