I have a 2006 KLX 250S which as the 1.9-gal gas tank. I have a 5-day multi-state trip coming up and this small tank is nagging at me.
I thought about carrying Rotopax cans and I thought about going with an oversize gas tank. The only tank I found for this bike is the Clarke 2.7-gal gas tank.

For those that battled this road before me, what have you found to be the best, most reliable way to carry extra fuel?

 

If you're going to put on a larger tank and want the most fuel capacity get the Acerbis 3.7 gallon tank. It's originally designed for the klx300r, but it fits the klx250 just fine. Only issue is the choke **** on the carb hits the petcock. That's resolved by either bending the choke **** or triming it for clearance. I've had this same tank on my 2006 klx250 for the past 10 years and it doubled the range.

 

1994klr250, that's awesome and good to hear. That tank has may attention. I see it comes with a cap for the tank. Does it also come with a petcock?

 

Yes it does come with a cap (non locking) and a petcock.
https://www.kawasakiforums.com/forum...s-tanks-35194/

 

After reviewing my options, I ended up ordering the Acerbis 3.7 gal tank. After...I ordered a Rotopax 1 gal can. I guess I have the fuel capacity thing covered. LOL.
Thanks for your help all.

 

Never hurts to have just a bit more gas. If you're not travelling alone, the RotoPax would work well to help another rider should they run out on the trip.

 

I use the Acerbis 3.7 on my '12. I've used it since 2013, and aside from the petcock mod, the only other thing I did was to trim the front edge of the side covers to clear the tank.
I use the bike for backwoods riding, and having under 100 miles of range really limits how deep into the woods I can go.

 

I received my tank and should have it installed tomorrow.
I was looking at the shape of the tank and there seems to be a lot of gas below the petcock. How much gas is unusable? I guess what I'm looking for is...for the 3.7 gal tank, How much gas is in the tank when it's time to switch to reserve? After switching reserve on, how much gas is left when the bike runs out of gas?

 

I've ran mine dry before. There's about 0.1 to 0.05 of a gallon of unusable fuel left in the lower part of the wings. You can lean the bike over to the left and it will get you a few extra miles in an emergency. Reserve is about 0.6 gallons. Main tank is 3.0 gallons before reserve.