Originally Posted by Werloc

Dash, This is "about" (give or take a few pages) where they start talking about it. It's almost 700 pages all about the KLX250. A good long *** thread to go back and read on a rainy day. Tons of info.

Long term KLX250S review | Page 653 | Adventure Rider

Originally Posted by dpippin

You have to modify the throttle actuator on the pumper carb. You need to cut off the top part of the actuator wheel to clear the fuel tank. Then you only use the pull throttle cable for throttle operation. Once you make this modification everything fits fine.

Mikuni TM 36-68 Pumper Carb

Doug

Originally Posted by jeepkevin

I was in the same boat. I have had the oversize tanks on other bikes and they worked just fine. My only complaint was that the added weight was over the front of the bike. On this bike I decided to go with the small PMR rack and add a 1 gallon Rotopax when needed. I redrilled the mounting holes on the rack so as to turn the gas tank sideways and move it as close to the seat as possible. This allowed me to install the factory vinyl pouch after the gas tank on the end of the rack. This set up makes a nice flat surface for me to strap my expandable back pack on to for whatever crap I need to carry.

Originally Posted by toomanytoys84

Painting a plastic fuel tank is a losing battle. I've never had one successfully stick. I have read that this is because fuel vapor leeches through the plastic and breaks down the paint.