I have read all the post on Clarke tanks and their fit and/or no fiton the KLXalong with seat problems andfor some the problem of getting it all in there. Here is my take on all of that.

I have just installed the Clarke tank on my 2007 KLX250. I started at 10:00 an I'm in here writing about it at 11:10. I have seen all the talk about things not fitting and being very tight to get it all connected. I scanned over the directions that came with the new tank and folded that up and put it in the drawer.

The easy and quick way to take out the original tank and not mess with getting the fuel out while it's on the bike is to just turn the petcock to the Off position. Reach in with a pair of long nose needle nose plires and grip the retainingwire where the fuel line attaches to the Carb, and pull that back off the nipple and use a flat blade screwdriver to push behind the edge of the tubing where it butts next to the carb and pry that loose while rocking the fuel line back and forth. It's turned off now and will not leak fuel all over.

Using an 8mm socket, remove the two 8mm bolts that hold the petcock to the frame piece. Remove the two side bolts and the one rear bolt and pull the tank up and off the bike.The long black vent tube will pull up with the tank. Then I took a funnel and a fuel can outside the shop and easily dumped the fuel out of the tank and into the fuel can. Then I turned the petcock to the Reserve position and drained the last little bit from the tank to the fuel can. Done.

Back into the shop, now that the tank is empty it's easy to get to the tubing and brass fittings. I used two pair of needle nose plires to pull the retaining wire ends out enough to loosen and pull them down the fuel tubing. I removedtheretaining wires and tubingfrom the brass fuel nipples from the old tank in the same manner as before and used the supplied 'O' and Hand screwed them in using a 17mm socket. Then tightened them down a bit with the socket and handle. Then I installed the fuel lines from the petcock back on the new tank and pulled the retaining wires back over the lines to their original positings.

My tank is Black and it fits pretty well. I had tested the fit before I changed all the fitting from the old tank to the new one and even attached the seat and one of the front pannels. The seat fit nice and I had no problems in lineing up anything. I put about a gallon of fuel in and looked closely for any leaks. I found none so cranked it up. So less than 1½ to change out the tank and write this. Going to ride after the Braves game this afternoon to see how the mileage goes.

Ride Safe.

 

Sweet man! I'm happy for you. Love it when things go nice and smooth.

 

The installation was easy enough.
IMHO the fit is poor on my bike.

But it's on and I really appreciated the extra "juice" today.

Lets put it this way, the original tank will never again adorn my KLX.

 

I was looking around at fuel tanks and here is a place that has all three for sale in one spot.Acerbis, Clarke & IMS available JustGasTanks.com
w/ free shipping over $150 & no tax outside of Kalifornia.

 

Yeah, that's where I got mine. $194.75 for the tank with no tax and free shipping. Looked for a few weeks to try and find if there was any place that could beat that price.I didn't find one and they were good on the service also. Came in within the week.

I'm satisfied on the fit and it hasn't leaked a drop so far. The feeling of security with the GPS and the extra 45-50 miles of fuel and the .380 makes for a better ride alone in the woods.

 

TC,
Im with you on the .380,hehe I carry the G27 .40 small and compact.


WD

 

I'll take my Gerber Gator drop point. STEALTH.

 

Hey west,
Just like Mic Dundee!

 

"That's not a knife...."[8D]

 

Yeah man!
Paul Hogan lives down the road from me in SB.