I meant to post this up sooner but have been too lazy. I bought a factory second tank from Clarke about two months ago. I was kicking around on their website and saw a listing for factory second tanks. Lo and behold there was a listing for the 06-07 KLX 250s. Model #11480 on sale for $110. That's 30% off the regular factory second price of $156, and I don't know how many %'s off the normal perfect tank price of $218! Day-um! that's over a hundred bucks off the regular price. I called Clarke to ask what to expect if I were to order one of these. Chris, there at Clarke assured me that the tanks were structurally fine and only had some cosmetic problems. He said the defects were barely noticeable and, on the KLX tank, would be covered by the shrouds. He said there was some discoloration where the mold lines were sanded smooth or something. As long as the thing didn't have a big gouge in it and it wasn't half pink I didn't care. I didn't know if I could justify spending a $100 just to be able to carry an extra .8 gallons of gasoline. So here's how I did that OK, .8 gallons doesn't sound like a lot of extra gas, but compared to the stock 1.9 tank it's about 30% more. 30% sounds better than .8 gallons. Ordered the tank.

Clarke Plastic Gas Tank Factory Second #11480- [FACTORY SECOND #11480] - $110.00 : Zen Cart!, The Art of E-commerce

When the tank got here I looked it over for the blemishes. I really didn't see any thing wrong with it. Since I knew it was a second I looked closely for anything that might be wrong. The only thing I could find were some tiny specs here and there. Nothing I would have even questioned on a "good" tank. Very happy . Weighed the tanks and if I remember correctly the stock steel tank was 5lb and the Clarke was 4lb.

 

Clarke tank re-uses the factory pick ups.

Here is how your reserve tank works. Long pick up is "on" and short pick up is "rerserve".

 

As noted in every other post about the Clarke tank the fit on the 06-07's isn't perfect. The tank is designed to fit the old KLX 300 and there have been minor changes as the years have passed. Do not let this scare you away, because everything bolts up fine when mounting the tank. The only spot I had to improvise was with the screw that the front of the seat slides over. The one Clarke sends is too short for the KLX250s. I used an old mounting bolt from something I had removed in the past, one of the rear cover washers, and a couple bushings to make it work.

 

 

I should add that I got the natural color tank. I like the way it looks, and the fact that I can see where the fuel level is if I look hard enough. FYI As I write this, Clarke only has 3 more of the factory second tanks left. Better ask your wife if you can buy one,,, quick.
Dan

 

I ordered a black one should be at home when i get there from work today, but it wasnt a factory second tank.

 

I really liked the extra capacity of the clark tank but I did notice the extra weight of the gas when full. So I put a 1/2 gallon in at a time and marked it with a marker on the side of the tank so I did not fill it all the time.

Also keep an eye on the brass insert on the bottom of the tank. Mine leaked there. Clarke replaced it of free. Great warranty service.

 

You noticed the extra 6lbs of weight? really... 6 lbs is nothing... i bet i have had 6lbs of mud on my bike...

 

Thanks for the heads up Dan888

Just ordered my factory second, got one of the last three. Mine will be clear too. In another few weeks or so, I was going to order one anyways, you just saved me like $70.

Sweet.

 

Dang, I wish they made one for the '09.

Me and likely a few hundred others that is...