The Acerbis install isn't going as simply as my dry fit had led me to believe. I think the two wire harnesses that go over the frame are going to have to be re run under the frame. Everything fits GREAT except the two bolt holes in the middle. They lack about 1/4 inch high and to one side of getting the threads to bite.

 

Yeah. . . . now THAT'S some quality manufacturing . . . . Thanks, Acerbis!

 

RP. Did you skip the two screws that go into the sides of the tank ?

I can't get mine to line up but the tank seems rock solid with the two front braces and the rear screw.

 

Quote:
Another fuel increase tweak. My new tank seems to have fairly concave walls on the outter wings. Would it be feasable to gently heat the tank side and put a little air preasure in it to curve the sides out more convex and let it cool that way.

I think heat and air would work if you did it right, but I don't think it would gain you all that much volume. You would have to heat the tank evenly and the tank walls would have to be a consistent thickness before you could expect it to expand evenly. Good idea, but I think there are too many places where it might go wrong and possibly ruin your tank. +1 to what Redpillar said "3.7 gal is a fair bit of fuel" , you already doubled the stock volume.
I sent you a PM.

 

Just a thought......always thinking.

I did heat the bottom of the tank to make a concave pass through for the wire harness so it wansn't smashed between the tank and frame. Still couldn't get those two middle bolts to line up though.

 

I got mine to go in by removing the metal insert that goes is the gromment in the frame. I also read of an installation where the dude cut the rubber grommet in half and put it back in so that the bolt fits through the hole. If you **** with it it will go. The wire harness just has to be routed around a bit I will look for a link for you.

 

In fairness to Acerbis this tank is technically for a KLX 300. It's VERY close. About 1/4 inch high and to the side.

The tank seems solid thought. I've still got some things to do before it's permanently mounted.

Some people say they don't care for the Acerbis look but I think it looks great.

 

The tank wraps around the front and protects the radiator right? The problem I had with my KLR was when I would crash in the sand the side shrouds would rip off, seems like that might happen with the KLX too? Thinking the tank might fix that. Also the choke problem is kind of turning me off.

 

The choke is hard to reach with the stock tank already. It's no big deal though. Mine still works, it's just a tad harder to get to. I'm going to lengthen the choke shaft an inch or so which should put the **** in a much better possition than the original. I don't know yet whether I'm going to thread the choke shaft and lengthen it with a tube or whether it might be simpler to just remove the ****, solder on an extension and stick the **** back on.