Has anyone ever attempted to mod a stock fuel tank for more capacity?

It seems that the aftermarket can't/won't get it right as far as fitment. Used stock tank pop up fairly often & it seems like it couldn't hurt modifying.

 

Since you have the '07, what's the fitment issue with the Acerbis 3.7 gallon tank?

 

I'm only going on what I recall from reading old threads on fitment issues. I want a drop in without rerouting wires,mounts or clearance issues.

My bike has been in hibernation for a few years & I want to get back on/off road again. After the exhaust/carb mods, fuel economy went down the tubes.

 

The fitment issues are really only with the '09 and later models. A slight repositioning of the fuel line and pushing the main wiring harness down even with the frame backbone is all that comes to my mind. The '06/'07 KLX250 is basically just like the off road-only KLX300, so fitment just isn't a problem.

On the metal tank, yes, a welder with the right skills can build, mod, or cut on the stock tank, but fuel is a tricky thing to contain. Vibration and impacts from a dirt bike tipover cab be hard on a metal tank, much less one that has been hacked on. Do yourself a favor and get the Acerbis.

 

200-300 bucks isn't pocket change but I've wasted money on more stupid things. I'd say pick up an aftermarket tank and try it out, you won't be disappointed. If you can't stand it then throw it up on the forum or CL and you'll get at least half your money back. Just my 2 cents.

 

I have an 06 (same as 07).

Acerbis 3.7 aftermarket tank fits perfectly fine. Remember you can rotate things (like carb/choke orientation a bit) and move/arrange the single fuel line really easily. Unlike stock tank you only have one fuel line to worry about.

I have a cheap 90 degree fuel filter attached to my fuel line (so there's a bend), so I have no issue with choke or anything being in the way. I had dremel'd down my choke **** (so it was a half circle), but this ended up being completely unnecessary.

There is only one issue I'd say to watch out for:
My lime green Acerbis tank is NOT the same shade of green as my KLX. Some people's match up perfectly, while others do not. Mine was ordered off eBay so I don't know if it was an older run or what.

I do not know how to tell you'd get the right one. I wish I would've gone with the black

 

Yep, I'll second or third that, mine slid right on my 07. I have a bb mikuni carb and the choke **** hits the petcock, but not enough to cause problems, I just have to hold it out for the first couple seconds for cold start. I also tweeked one of the lower braces so it cleared the radiator.

 

There's an overseas seller on ebay that has Acerbis knock-offs. justgastanks dot com is a great company to deal with.

 

I would've gone with justgastanks but they were out of stock and I would've had to wait over 2 months (with a rusty or leaky stock tank on bike in meantime)


OP, if you do go eBay route, I agree with above. Make sure it's not an Acerbis knock-off (mine wasn't, and it came from reputable US shop w full OEM package - bag, stickers, instructions, etc).

 

lets not forget the simple way to add more fuel