Here's a few pics to clarify what we've been discussing:

 

hmmmm....doesnt look like its touching really at all.

 

received my clarke tank thursday, and jumped right into the install. you all were right on the money. longest part of the install was draining a nearly full stock tank. install was simple and would've taken 45 minutes or so until one of the unattatched fuel hoses that goes to the carb flung gas into both my eyes. not one drop on my face, perfectly into both eyes, and nowhere else. i couldn't duplicate that feat if i tried (not that i'd want to, my nine year old had to lead me into the house like a blind person in such a hurry i was bouncing off walls, while my wife kept asking why daddy was acting so silly). looking back it seems funny, but at the time it burnt like heck. i would say wear safety glasses, however, i guarantee you can't do this to yourself. freak stuff only happens to me. correct also regarding the shroud fit. if you are someone who likes to stare at your bike, you'll be dissapointed with the fit. i was that guy, but after a day, i'm the new guy who is just happy having nearly a gallon more fuel. o-rings came with the tank and appeared to be much, much thicker than the stockers. no leaks thus far. did everyone reuse the stock clamps on the two fuel hoses, or safety wire or what? the tank came with a nice plastic clarke branded screw type cap, but no vent hose. i had to buy one of those shorty hoses with a one way valve on the end. tank feels a little wider, but height is close to the stocker, not much higher. i guess i flooded the bike with all of my fiddling. laid it on it's side for a minute, then started it up. working in that area, i must've also changed my idle settings, so that took a bunch of readjusting also. that's it for me, took it for a ride and all is well with one day in. oh yeah, one more item, getting the seat back on truly is a PITA now, but i guess that's a small tradeoff for what i wanted (more range).

 

I reused the stock clamps. You do not need a one way valve for the vent hose, any hose will do, the cap already has a check valve built in...I know, I tested it (don't ask, don't tell)

 

Ok guys,I am going to fix this problem, I made my own rack fo my 09,now I am going to make a one gallon 10" by 10" alloy gas tank to fit on the rack. Not sure how tall it will be yet. I will start on it in a few days,and I will keep you posted. Bob B (the old man)

 

Just keep this in mind...
https://www.kawasakiforums.com/forum...ghlight=danger

 

I sent my 1st tank back after 6 months. No questions, here's your new one.
My tank fits better than the stock one. That's enough for me to be 100% satisfied.

 

I'm on my 2nd one and I'm happy with it.

 

I've hade mine for about 9 mounths with no issues. As for the fit I put a couple pieces of foam to fill the gaps and needed to modify the length of the screw head for the seat toung. aside of that I'm very happy with it.

 

Just wanted to add one more data point to this thread for those considering the Clarke tank. I received mine (clear) last weekend and installed it yesterday and went riding...

• Fit and finish are overall excellent!
• Main fuel tap does indeed sit very close to a frame cross member, but the tank shouldn't move. I'll keep my eye on it, I'm comfortable it's good as is.
• Regarding the brass fuel taps that you remove from the stock tank and screw into the fittings on the Clarke tank: I found the smaller stock o-rings that nest into the grooves of both male and female gave a better seal than the larger o-rings that Clarke provides that don't nest. No leaks with the stock o-rings, and they fit perfectly.
• Regarding the flange on the radiator shrouds that no longer fits under the seat, I trimmed mine off thereby showing a bit more of the tank which I consider my "fuel gauge". I plan to put some Sharpie marks at the varioius fuel levels so I can better manage fuel when out exploring in the sticks.
• As others have mentioned the fuel cap already has a valve it so a simple piece of hose that dumps somewhere on the front side of the handlebars works just fine. Should Clarke provide a piece of tube just in the interest of completeness? Probably, no biggie though.

Sure is nice having that extra capacity, and being able to see it at a glance when deciding whether to go explore than one last trail/road!