Crash guards and aftermarket fuel tanks? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 17 Old 07-27-2016, 10:34 PM Thread Starter
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Crash guards and aftermarket fuel tanks?

Wondering if any of the crash bars/engine guards will fit with any of the aftermarket gas tanks(the plastic ones) for the 1st generation bikes. Anyone know? I want to swap my current tank, since it's not in the best condition.
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post #2 of 17 Old 07-28-2016, 12:07 PM
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Not sure but I ditched my Happy Trails Paris-Dakar bars when I bought my 6.6 IMS tank. Save's 12 lbs and the tank offers adequate protection IMO.

2 cents,
Dave
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post #3 of 17 Old 07-28-2016, 08:03 PM
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I bought my SW Motech bars from a guy that upgraded his tank.

I don't understand the 'tank provides adequate protection' argument -- These are plastic tanks and if they crack, you're out of fuel, and you're out a fuel tank, in the middle of nowhere, there goes your trip, period.

The risk of a cracked tank, due to no crash bars doesn't seem worth the extra gallon to me.
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post #4 of 17 Old 07-28-2016, 08:37 PM
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Quote:
Originally Posted by drumstyx View Post
The risk of a cracked tank, due to no crash bars doesn't seem worth the extra gallon to me.
Your call, individually drumstyx!

Actually, from reports of others, aftermarket tanks have proven rather crashworthy.

Our friend Peter on his 45,000-mile ride through the Americas, found his 10-gallon IMS more durable than his leg bone in a crash.

Anecdotal, sure, but . . . thump one of these aftermarket tanks when you get a chance--to me, they don't seem apt to crack easily; YMMV! (A little JB Weld oughta get you going, if they do, I reckon! )
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post #5 of 17 Old 07-29-2016, 01:23 AM Thread Starter
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I'm with drumstyx on that one, I think. My current tank is cracked all to hell because someone dropped the bike several times in its previous life. I'm fixing to get some sort of quick-fix to make it ride-worthy until I have the chance to go home and get one of IMS 6.6 gallon tanks. I'd rather not rely on JB weld. Especially since they don't sell it here! I'd feel much safer if the crash bars would fit over the IMS 6.6 gallon, since I will be doing that "middle-of-nowhere" type riding and a cracked tank would suuuuck that far from a town or anyone that speaks decent English.
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post #6 of 17 Old 07-29-2016, 07:52 AM
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Quote:
Originally Posted by TaiwanMotoGuy View Post
I'm with drumstyx on that one, I think. My current tank is cracked all to hell because someone dropped the bike several times in its previous life. I'm fixing to get some sort of quick-fix to make it ride-worthy until I have the chance to go home and get one of IMS 6.6 gallon tanks. I'd rather not rely on JB weld. Especially since they don't sell it here! I'd feel much safer if the crash bars would fit over the IMS 6.6 gallon, since I will be doing that "middle-of-nowhere" type riding and a cracked tank would suuuuck that far from a town or anyone that speaks decent English.
Clarifying, TaiwanMotoGuy, you have a cracked KLR650 AFTERMARKET PLASTIC TANK?

If so, best wishes on an effective temporary field expedient repair; afterward, nothing wrong with installing BOTH crash guards AND a plastic aftermarket tank, I reckon.

Nothing wrong with wearing both pants belt AND suspenders either, I suppose!

=====================

Seriously, JB Weld, the modeling clay-like variety in a plastic cylinder with its own hardening agent activated by kneading, can be useful for many things motorcycling-related. Besides a putative fuel tank repair, the stuff can actually repair cracked RADIATORS. Not a bad idea to carry a hunk of this stuff on board. Perhaps you can find a vendor who ships internationally; good luck.
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post #7 of 17 Old 07-29-2016, 10:53 AM
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Quote:
Originally Posted by drumstyx View Post
I bought my SW Motech bars from a guy that upgraded his tank.

I don't understand the 'tank provides adequate protection' argument -- These are plastic tanks and if they crack, you're out of fuel, and you're out a fuel tank, in the middle of nowhere, there goes your trip, period.

The risk of a cracked tank, due to no crash bars doesn't seem worth the extra gallon to me.
Experience dictates that the risk of cracking or damaging an IMS plastic tank is extremely low. In fact, after racing motorcycles with plastic tanks for 35 years (and hundreds of crashes) I've never cracked a tank.

....but, do whatever you think is right.

Cheers,
Dave
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post #8 of 17 Old 07-29-2016, 10:58 AM
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....and the reason I run the 6.6 IMS has nothing to do with the extra fuel. I run it because;

- it protects the radiator without the use of crash bars saving 12lbs
- it is impervious to dents
- it doesn't rust
- no paint to scratch
- I like the ergonomics better
- it can hold the stock amount of fuel at a lower center of gravity
- I can check my fuel level from 20' away
- It allowed me to get rid of the problematic factory fuel cap.



Cheers,
Dave
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post #9 of 17 Old 07-30-2016, 10:41 PM
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Quote:
Originally Posted by DPelletier View Post
....and the reason I run the 6.6 IMS has nothing to do with the extra fuel. I run it because;
- it protects the radiator without the use of crash bars saving 12lbs
- it is impervious to dents
- it doesn't rust
- no paint to scratch
- I like the ergonomics better
- it can hold the stock amount of fuel at a lower center of gravity
- I can check my fuel level from 20' away
- It allowed me to get rid of the problematic factory fuel cap.
Cheers, Dave
I have the 10.7 gallon IMS tank. I got it to eliminate the need for crash bars and the extra fuel range. I agree with Dave's comments on dents, rust, scratches and center of gravity. Mine is black (wish it was clear) and I have no problems with the stock fuel cap.

I dropped it in a soybean field in Saskatchewan and found that the tank doesn't provide the protection I expected it would. The tank caved in and folded in on the left front and left rear corners like a plastic milk jug. When the front folded in it took out the radiator and when the rear folded in it pulled the fuel line and broke the inlet elbow off the carburetor.

The tank came out fine with no dents, cuts or leaks. I stood the bike up and watched the tank slowly regain it's original shape like a beach ball being aired up.

I am still running the tank. I put on longer more flexible fuel line and am adding a 1"x1" square tube across the front between the two forward lobes and bolted to the center frame tube to hold the lobes out and protect the radiator.

Last edited by GoMotor; 07-30-2016 at 10:44 PM.
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post #10 of 17 Old 07-31-2016, 01:07 AM
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Quote:
Originally Posted by GoMotor View Post
I have the 10.7 gallon IMS tank. I got it to eliminate the need for crash bars and the extra fuel range. I agree with Dave's comments on dents, rust, scratches and center of gravity. Mine is black (wish it was clear) and I have no problems with the stock fuel cap.

I dropped it in a soybean field in Saskatchewan and found that the tank doesn't provide the protection I expected it would. The tank caved in and folded in on the left front and left rear corners like a plastic milk jug. When the front folded in it took out the radiator and when the rear folded in it pulled the fuel line and broke the inlet elbow off the carburetor.

The tank came out fine with no dents, cuts or leaks. I stood the bike up and watched the tank slowly regain it's original shape like a beach ball being aired up.

I am still running the tank. I put on longer more flexible fuel line and am adding a 1"x1" square tube across the front between the two forward lobes and bolted to the center frame tube to hold the lobes out and protect the radiator.
Impressive. Obviously didn't protect the bike, but I guess it's fine itself eh. On top of my protection concerns, I also run a magnetic tank bag on most of my bikes, which is kinda no good on a plastic tank.
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