CRF300 Rally 300 Mile Long Distance Fuel Range

Let me show you how easily you can give your CRF300 Rally a 300 Mile Long Distance Fuel Range with a quick Rotopax fuel cell upgrade. Most CRF300's are getting just about 70 miles per gallon. The Rally comes stock with a decent sized 3.4 gallon fuel tank which gets you a respectable 240 miles down the road. Adding a 1 gallon Rotopax gas can gets that long distance fuel range to just over 300 miles. And at that range you can confidently hang with any of your buddies on just about any other adventure bike. You won't be matching them gas stop for gas stop because the Rotopax is really a separate reserve tank. So the big benefit is more that you can venture off knowing that you can wait a very long time before searching for a gas station.
This install requires side racks which I review in a separate installation video. These are just some of the How-To videos that I have posted to help you build the ultimate light weight long distance adventure bike based on the ever affordable CRF300 Rally.
The Rotopax Can and Mount Kit are available at the following links:
RX-1G 1 Gallon Can: amzn.to/3QPAgDL
RX-PM Pack Mount: amzn.to/3BGX9Fb
I hope this video is helpful, I'm always delighted to get your questions comments and feedback.
Remember you can also find me at dualsportgarage.com/
Thanks for watching!
Note: I received no free product and I was not paid to make this video. This channel is subsidized in part by small commissions paid on some, not all, product links. And as an Amazon Associate, I earn from qualifying purchases. So it is helpful and very much appreciated when you use these links to support this channel.

[@MI-9]

Thanks for the video. I think it would be more convenient to fix the canister horizontally (turn it 90 degrees).

[@dualsportgarage]

I could see that working also …good tip …let me know how it works out, if you try it! Thanks!

[@ezekielchariot]

My bolts for that plastic rear rack do not stay as tight as when I first do them up so I had to modify the rack bracket holes by drilling larger holes and fitting steel ferrules and washers under the bolt heads so that upon tightening we have metal crushing against metal rather than crushing plastic which does not have elastic memory and lets the bolts become looser. Not any more. Annoying having to fix something after 1 day that does not incorporate normal engineering practice from the manufacturer.

[@dualsportgarage]

You made me go check!… I found no issue with any of these fasteners. So far everything things seem to stay put nicely on the rally 300. Thanks for the feedback!

[@LowsJuan]

One advantage I see with this is the ability to vent the rotopax without dismounting it, this is required if you are doing large elevation changes or passing through large temperature changes . (more for multiday trips) Flat mounting on the rear rack means it has to be removed to do so. Let alone removing all your luggage to use/refill it. The venting thing prevents longterm cap failure/leaking. You didn't mention or show the swingarm/chain clearance?

[@dualsportgarage]

Thanks for the thoughtful comment…clearance looks good …but when I replace the shock in the next couple weeks I will bottom the swing arm out and see exactly how close it comes. I will add my observations to the comments. Thanks, be well!

[@redpine25]

@@dualsportgarage will the rotopax touch the chain guard?

[@dualsportgarage]

The chain guard isn’t actually close enough to touch.

[@redpine25]

@@dualsportgarage Thanks!

[@thefatcrofter4753]

Hi, I have just completed 29710km across Canada and Alaska this summer including Dempster Highway, Top of the World Highway and Dalton Highway on a CRF300l with outback mototech pannier frames and rack. I had 27ltr Tusk Hard panniers with the 1 gallon rotopak with zero issues but......... When I came to fit it I did as the way you have in the video ie as per instructions however when you fit the rotopak there is not much thread contact on the rotopak retaining bolt, as in the part which clamps down on the rotopak itself as the rotopak contacts the frame face. I fitted the x frame on the inside and you gain 'extra' thread of the nearly 18mm of the frame tube. It also has the benefit of not having the bolt heads proud when using hard panniers. I feel the instructions would be ideal if you are mounting the rotopak on the outside eg if you were day tripping or using soft luggage. Other than this the only niggle I have is that the front lower mounting points on the pannier frames are open slots they would be more secure if they were slightly elongated closed slots as I did need to adjust them a couple of times as they edged out a couple of mm. At least if it was a closed loop it could not pop out.

[@dualsportgarage]

Excellent feedback, both valid points, thank you for sharing. By the way your trip sounds totally epic! How long did it take you?

[@thefatcrofter4753]

6 months and it was epic! Managed to get a few weeks canoeing in too. Its sounds a lot of km but i didnt ride every day most days 350-400ish km depending on distances between places most was 670 by accident! I left it in storage in Whitehorse and am going back over to take it back east next summer and go to Labrador and Newfoundland theres a horizons unlimited meet start of Aug

[@dualsportgarage]

the HU event looks interesting...my riding buddies say NL and Labrador are absolutely spectacular...who knows I might just see you there!