It is a gravity feed tank. It has it's own petcock with NO reserve, so we will run this tank first, then switch to the main tank. It will allow the KLX250 a full 3 gallons of fuel. The coolant catch bottle is replaced with another, slightly smaller bottle, we are making up a mount for it now. The battery isn't affected.
The material is 5052 T3 aluminum. This tank is bolted to the bike in 4 places, the plan is to do it with 3.

The welding is much better on the next 2 tanks, the tank shown at the beginning of this thread.

Please bear in mind, these first 3 tanks are for our use, and throughout the month of June, we will be testing them in Colorado for hundreds of miles of trail-riding. After that is accomplished, a decision about this will be made.
Bill and I both think these will be a "Go"
Testing in Colorado should tell us.

 

That's a pretty cool looking tank you have there Bake.

 

I likeee.. Now make the lowboy pipe header,midpipe, bracket, and the matching right hand tank and Ill be first in the queue. Only kidding. Great stuff mate.

 

I hope ya'll do decide to sell these and that it will fit the 09 (I don't believe that there is any reason it shouldn't).

 

You Australians I know can appreciate this stuff. Thanks to each of you for the kind words. I'm bracing myself for the "smells like ***!"

Fuel range is a good thing.
That is in fact where I want to take this.

 

Very nice, makes me wish I had an 07.

 

I think our dealer can be convinced to remove a number plate so we can check on the fitment to the '09's
I'd be able to tell by just comparing the tank to the bolt arrangements on the '09.

 

little big for my taste (few inches shorter would be nice, but a gallon is a lot for this bike). maybe once i mess with the look of the bike and get a bit of a dakar look going on it will fit me better. does this work with aftermarket tanks?

 

It's a gravity feed with it's own petcock. It won't matter what tank you have. Just use the Aux tank first and when it runs out (no reserve) turn your regular petcock on and your good to go again until you hit your normal reserve.

 

Or just have both petcocks open and switch to reserve once, but I suppose it might be better to burn the weight off the *** end first. I know a gallon of jet fuel is close to seven pounds, so I imagine gasoline is only slightly lighter. On my longer expressway runs, it probably wouldn't matter much though.