I just ordered a new Clarke 2.7Gal tank for my 2007 KLX250S.

Any tips or things I need to know before I attempt to install it? It looks like I can re-use the factory shrouds, at least if the pic on their site is accurate...

Any clearance problems with the Carb or Seat I should know about?

Just wondering so I have everything set up ahead of time if I need to make any mods...

 

Just check very carefully for clearance issue. I can't remember exactly what I did but the petcock touched the frame (tube between the side frame pieces) and I had to shim something somewhere and I might have even dented in that piece a little.

 

I've had a Clarke tank on my '07 for a couple of years now with no problems. I didn't do anything special when installing it, but there are a couple things to watch for:

• The radiator shrouds each have one long screw (they hold the shroud to the radiator) make sure you don't drive these into the tank.
  
• The seat has a clip underneath the front tongue that clips onto a screw head on the tank. I could never get this to engage on the Clarke tank. It's never been an issue, however, and if you can't get yours to hook up don't worry about it.
  
• The fuel lines near the tank outlet come really close to part of the frame. Make sure they're not actually touching the frame (see pics).

 

thanks for the information guys!

 

Even though i had issues with the way it fitted in relation to the frame rails, I've had no problem with it.
I'm sure it should be sitting on the rail as the stock tank does.



I also had trouble with the seat popping out of the tank clip which i found a real pain in the dirt as the front of the seat moved around.
Fabbed a elongated washer which did the trick.

 

I saw some posts over on TT that spoke about the seat not fitting so I thought I'd use a longer screw but, after thinking about it for a bit, the elongated washer is probably a better way to solve it.

Thanks for the info!

 

I cut the edge lip off of the shroud for a better look, the new tank does not let the shrouds fit perfectly. If you get the clear tank you can even see you fuel level when you trim the edge. I used a razor knife to cut it off. I also used a longer bolt for the tank bolt. Just experimented with a few different sizes.

 

At full steering lock the lower bar mounts touched the tank, steady hand and a die grinder fixed that.

 

Poor mans fuel gauge.

 

Ohh that's nice to know. I'll keep the die grinder handy in case I need it.