<EDIT>USED IMS 3.2gallon (#113124N2) INSTEAD<EDIT>

 

I ended up going with the ims 3.2 ims (113124n2) for the older klx250 and klx300 bikes. Just got done fitting the 3.2 ims tank on the 06 klx250s I used a guide I found on AdventureRider forum and also a post on here by someone named flyingfinn, but the photos no longer show up on their posts. So I figure with all the knowledge I have gained from the forums I'd return the favor. Hope it helps

 

I recommend a petcock that has nipple on the left so the fuel line can bend without kinking to reach fuel inlet on carb. The petcock for the klx300 still hasn't come in so i used my old klr250 one and it fit perfect.

Disconnect harness all the way to tail lights on both sides that run down side of frame. Also snake the coolant overflow down the exhaust side of frame and hook around behind airbox with all the wires for tailights etc then to underneath battery box up to resevoir. It will be very close be sure to use a clamp.

Trim off the hook that was under my stubby finger. Not the throttle cables Goober! I used this insulation tape stuff (I forgot what it's called) to help cushion the tank and support it some. I ended up putting some on the top side where the tank could come in contact with frame.

Where wire harness meets break off the hook.

Move this out of way for now. Will have to mount somewhere else.

Will have to make some tabs that go up about an inch or two to mount coil. There is a recess in the ims tank that it should fit and still have some clearance. This tank is a very tight fit so I used some cherry flavored lubricant and greased up the slides. With a little love and some wiggling she slid into place. I will also note there is a hose clamp for the radiator crossover that I had to reposition because the head of the bolt on the hose clamp rubbed the front of tank.

Keep harness nice and tucked in to frame

Same on this side. Radiator overflow hose going back behind airbox to battery box to resevoir.

Klx300 or klr250 petcock works.

What she looks like mocked up.

Notice the nipple swivels which should help keep clear of carb. I have noticed the damn tps sensor is in way of the petcock nipple. Even with it being able to manipulate the nipple its a tight fit. Might have to attach hose and clamp first before installing tank.

 

I'm still waiting on a few more things to come in Mail to finish up. I'm in the middle of doing fork seals at the moment. The stock fan can not be reused. You must use aftermarket fan. Something slim. I'll post back with what I end up using.

 

I went and mocked up the radiator shroud plastics and I might have to make some bushings or something to secure the plastics to tank. All in all looking good!

 

Alright you filthy animals! I purchased new fans and made a bracket out of aluminum.

 

My welds look like crap. No argon so i was forced to use my sa250 to stick weld them. Burned a little hole on top but should hold.

Brushless dc 12v fans.

Used scrap aluminum that was laying around my yard.

 

 

 

Nice job! I appreciate all the details you gave in terms of lines that had to be re-routed, as well as needing a different fan set-up (would probably be a deal-breaker for me). I'm sure you're going to enjoy not having to stop every 90 miles to get gas. Currently I am running around with a quart-size spare fuel bottle on my '09 KLX250SF, an extra gallon would be real nice.