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Discussion Starter #1
As my username suggests, I have learned the value of having extra go-go juice on-hand in case I run out (yes, the hard way). I just bought my 2001 KLR with the stock tank last fall, have a healthy dose of mod-itis, am handy around the garage (haven't tackled welding yet, but hopefully someday soon), and am investigating what my options are for making this happen. What I have learned so far is this:

1. IMS makes a great product (minus the early hiccups with the newer 10 gal tank)
2. HT crashbars aren't the best, Givi or ok, SW Motech are tops
3. Some say the IMS tank provides enough rad protection, others say not.

I was in a wreck last year that wrote off my cruiser (damn minivan driver not doing a shouldercheck before pulling out of the slow lane!), and without a set of Cobra crash bars I could very easily have lost my right leg below the knee. That said, I am a HUGE fan of crashbars. I know crashbars on a KLR serve a slightly different function than on my cruiser, but I'm reasonably certain I still want to do both mods (bigger tank AND crash bars).

I'd like some opinions on the IMS tanks, and what (if any) crash bars might fit. I can only find info on a 6.6Gal and a 10Gal. tank from IMS, and I'm not liking what I'm reading about the issues with the 10 (leaking). Suggestions for different setups, brands, and/or sizes are definitely welcome!
 

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I could be wrong, and if I am I'm sure someone will correct me, but it's my understanding that the IMS tanks provide protection equal to the crash bars. I don't think (again, I'm not positive so someone please correct me if I'm wrong) you can get any crash bars that go with the IMS tanks due to the added width. I don't know anything about and haven't read up on the 10 gal tanks so I have no opinion on those. I would sure like to get one of those oversize tanks some day, but quite frankly, in these parts (my area) gas stations aren't that far apart so there's really no excuse for running out :).
 

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gascan -

I've had no issues with my 10 gallon tank. There have been some reports of poor fitting at the petcock, but mine seems to be fine. IMS may have made a correction. I'm using a Raptor 660 petcock.

The Happy Trails nerf bars could be modified to fit by someone with decent fabrication skills.

r





You'd need to fab new cross braces and a toggle of some sort for the bottom, as the bars need to be spaced about an inch outboard.

The "inch wider" thing might make the SW Motech bars too tight.

By the way, the IMS tank has a very stout brace at the bottom of the left side to help support the tank and protect the radiator.

T
 

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I'm very happy with my 10 gal. IMS. The first one I got had a pinhole leak(very early in production) but that is the only one I am aware of. I wasn't happy when it began leaking but doing a search revealed that other brands have leakers as well. IMS replaced the tank without any issues. The second tank has been great for over 5000 miles. It's been down a few times off road with no issues whatsoever. A friend on another KLR loaded with camping gear fell on my bike and the tank shows no evidence of the mishap. I have a Raptor petcock with extended tube on mine and hit reserve at about 365 miles. If I was going to setup another KLR,the IMS tank would be the first thing I purchased for it.
 

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It is kinda cool to ride all day long and then think, well, maybe I'll get gas tomorrow at lunch. ;^)

T
 

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after installing a few swmotech bars on mine i think they could be be spaced out and fit the added width of your tanks ok . you would need to upgrade the subframe bolts but its a good thing anyway .
 

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I have the older (6.6gal?) IMS tank on my '05 and started working on getting crash bars to fit around the tank with the help of a friendly welder guy. Then I decided I didn't want even more weight on my KLR so I put the project aside. Crash bars over the IMS tank are really cool looking (which was why I wanted to do it) and are heartily approved by the Department of Redundancy Department. I'm not sure they're worth all the extra weight though. Ymmv of course.
 

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My 6.6 tank has has a bunch of ummm naps lets say ... a few scratches here and their .. bit its still solid . i would not bother with the bars on mine . Also the only thing holding my tank on is the two bolts under the seat , i did not install the rest of the brackets .
 

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Discussion Starter #9
Thanks for the feedback guys! I'm leaning towards the 6.6 and leaving the crash bars aside on this one. Now all I hafta do is troll the classifieds until somebody sells one.

Any of you guys looking to "grow" from a 6.6 to a 10 Gal. ?!?!?! :evilgrin0007:
 
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