Fuel tank - 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 11 Old 07-21-2019, 10:59 AM Thread Starter
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Fuel tank

Hey guys I'm looking for a different fuel tank for my klr 650 it's an 05 does anyone have any photos of what they have or any input
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post #2 of 11 Old 07-21-2019, 11:07 AM
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The IMS 6.6 is the gold standard in aftermarket tanks for the Gen 1. No nerf bars required, but the JNS radiator guard is recommended. It's recommended no matter what you do, even with a decent set of bars.

It comes in translucent and black. This is the black one. @DPelletier has a translucent one.
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post #3 of 11 Old 07-21-2019, 11:24 AM Thread Starter
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Looking to do something like this but dont know the tank
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post #4 of 11 Old 07-21-2019, 11:55 AM
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That might be something like an ~'80 Z1R tank.

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I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
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post #5 of 11 Old 07-22-2019, 02:38 PM
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The early '80's GPZ's used that basic shape of tank also. The Z1R tank is probably Rarer than hens teeth, probably larger than necessary also.

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post #6 of 11 Old 12-26-2019, 06:58 PM
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post #7 of 11 Old 12-28-2019, 08:03 PM
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I've got an IMS 6.6 on a Gen 1, love it, easy & quick on/off, a little more capacity - what's not to like!?

Safari tank - on my back-up KLR, I installed a humongous Safari tank that came with a KLR I bought from mc salvage. This tank is huge. I've not yet filled it up all the way, but although it's advertised as 32L, I've read guys report it balloons over time, and can hold as much as 38L! In this pic, I've marked the 15L level:

Mounted on a Gen 1:



Front view on my Gen 2:



Here's a shot of the clearance to the exhaust (could benefit from a heat shield IMO). Note the stainless steel cross brace to support the bottom wings of the tank:



I used a piece of thin inner tube between the cross brace and frame downtube to prevent damage:



The US webpage for Safari claims the tank is compatible with both Gen 1 & 2. That's not quite true - the Gen 1 rad fan sticks back further, jams against the tank, wears into it over time, makes the tank difficult to push forward enough to get the bolts in (won't line up easily). I made a "low profile" fan, taking the fan motor out of a Gen 2, putting it in to a Gen 1 fan bracket, soldered on a Gen 1 fan connector I robbed off a bad fan assembly:



This is the clearance I got by doing that:



I got a genuine 500 km range on one tank with the IMS 6.6 on my Gen 1. I should get close to 800 km range with the Safari!

KLr650 safari fuel tank Safari Tanks USA

Edit - just remembered, installing that Safari tank on a Gen 2 wasn't totally plug 'n play, it is necessary to remove the AIS and cut the mounting bracket for it off:


Last edited by GreatWhiteNorth; 12-28-2019 at 09:47 PM.
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post #8 of 11 Old 12-28-2019, 08:10 PM
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it fits the gen 2 but has major clearance issues. none of the brackets work except the the one that bolts it to frame. radiator corner has to have heat shielding as it rest almost on the tank. i called ims and told them. them didn't seem to care.

souper doo fyi helped
https://www.souperdoo.com/STUFF%20TH...emi-round-hole
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post #9 of 11 Old 12-28-2019, 08:18 PM
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this is how close it is


i ended up but 4 small squares of high temp silicone to insulate


i sent these pics to ims too. i spent hours fabbing and bending fan bracket. stock bracket location impossible with ims tank

Last edited by maverick9611; 12-28-2019 at 08:21 PM.
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post #10 of 11 Old 12-28-2019, 08:37 PM
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Quote:
Originally Posted by maverick9611 View Post
this is how close it is


i ended up but 4 small squares of high temp silicone to insulate


i sent these pics to ims too. i spent hours fabbing and bending fan bracket. stock bracket location impossible with ims tank
That's a lot of work to make that IMS tank work on a Gen 2! The IMS 10 gallon tank is made for Gen 2 - why wouldn't you go for that instead?

We should swap tanks (kidding)
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