I own & ride a 1987 model. But I've been working on K bikes since 1976.

But, as I understand it. The IMS 10 gallon fuel tank is the exact same shape & size on the Exterior surface as the 2008-UP Gen 2 fuel tank & shrouds combined! That is how it holds 10 gallons.
So, I'm fairly certain that the SW Motec guards for a Gen 2 will fit any year of KLR650 fitted with the IMS 10 gallon fuel tank. (including my '87 if I was so inclined.)

Maybe I should ask, which IMS fuel tank you are referring to?

 

Looking at getting the 6.6 gallon tanks

Sent from my SM-G935F using Tapatalk

 

Did not know that IMS built a 6.6 gallon tank for fitment on a Gen 2. Compatibility question still remains.

 

the 6.6 is a Gen1 tank....but as per the other thread, Happy trails says that IMS says it'll fit on the Gen2. It obviously will as I've seen several Gen2's with the IMS. It makes sense as the two OEM tanks are the same except the shroud mounting brackets. As you know the Gen2 rad is a bit bigger.....mounting pces that bolt to the rad are probably different but most of us don't use them anyhow (the "pucks" and two bolts under the seat are enough).

My guess is that some minor tweeking is required - but nothing much.

Dave

 

I'm not sure why a 6.6 wouldn't fit on a Gen 2. It would look incomplete and all, but it should physically fit on the bike.

Probably comes down to whether or not the radiator can be properly supported.

 

On our Gen1's we don't support the rad at all; it's just held on by the rad support bolts to the frame (and I use the JNS rad guard). People have opined that bolting it to the tank increases the risk of the rad being damaged in a crash - I tend to agree.

.....and whadya mean looking incomplete? it has the shrouds built in, after all.

Dave

 

Dave & Tom,
The compatibility Question is, Will Gen 2 SW-Motec crash bars fit on a KLR650 fitted with a IMS 6.6 gallon fuel tank?

 

I know, but it is kind of a moot question. IMS tanks do a pretty good job of protecting stuff as-is and few, if any, put bars on them.
@DPelletier, The IMS 10 has a lower strut to space the tank out form the radiator. By incomplete, I meant in an aesthetic way. The 6.6 doesn't complement the lines of the Gen 2 in the Reubenesque way that the factory plastics (and IMS 10) do.

 

I know, but it is kind of a moot question. IMS tanks do a pretty good job of protecting stuff as-is and few, if any, put bars on them.

@DPelletier, The IMS 10 has a lower strut to space the tank out form the radiator. By incomplete, I meant in an aesthetic way. The 6.6 doesn't complement the lines of the Gen 2 in the Reubenesque way that the factory plastics (and IMS 10) do.

Tom, my experience with the IMS 10.7 gal tank is that it has close to zero structural integrity. I bought it with the idea that the low wings on it would protect the radiator and I would not need crash bars. When I dropped it the tank folded in like a plastic milk jug. After crushing the radiator it slowley morphed back out to its original shape with no damage to the tank - just the crushed radiator.

I now have a 1" square tube from side to side mounted to the frame tube with some 1-1/2" x 1-1/2" angles. It supports the tank wings in a crash and provides a mount point for the outside lower corner of the radiator and for highway pegs. I have dropped the bike several times with this arrangement and had no problems.

I wish I had bought the semitransparent white rather than the black so that I could see the fuel level.


Dave, my IMS 10.7 did not come with "a lower strut to space the tank out from the radiator" which is why I added the 1" square tube.

 

Tom, I was half joking but I'm not a fan of the Gen2 aesthetic so I guess I'd view the 6.6 as an improvement.....but I get your point.

Dave

 

Understand. My opinion on KLR aesthetics is that both Gens are uglier than a mud fence. The best I can say about the Gen 2 is "Reubenesque'.

 

hey, wait I think my Gen1's are kinda cute......the Gen2 looks like the bastard love child of a Gen1 and a ZX6R! LOL




Dave

 

Was that a CV carbed ZX6R, Dave?

 

Strange, my tank came with such a strut for the radiator side. I made a beefier support for the other side than what IMS provided. The tank can't be expected to protect anything if it doesn't have these supports.

 

I went back and looked at the IMS instructions and now recall the piece they call the support bar under the radiator. The little 6mm bolts that attach it didn't stand a chance when I dropped the bike in a corn field in Saskatchewan. The tank wing folded in and back and the bolts pulled right out of their threads and the radiator folded.

The rear of the tank folded forward at the petcock and the short fuel line cracked the new nonreplaceable carb inlet ell (requires a new $$$carb). I used all my JB Weld and made it 10 miles to a small town leaking fuel and with no coolant. Bummed a ride to a larger town and got a lot more JB Weld. The JB filled a 1/4" gap in the radiator outlet tube and several smaller leaks, but nothing would stick to the cracked polypropylene fuel elbow. So, I limped along with the leak down to Lander, WY where Mr. Pdwestman helped me find a Harley replacement for the nonreplaceable elbow (can be pulled with Vice-grips).

So, now I have a new Myler's double thick radiator, a 1" square tube tank brace and a longer more flexible fuel line with a Harley inlet ell.

 

Please advise...
I would like to put a 10gal tank on my KLR, but as I understand it, the IMS tank is plastic. Does anybody know of large aftermarket tanks that are metal and therefore street legal? Does anybody use a plastic IMS tank on the street and find that the highway patrol doesn't hassle them? DesertRat

 

My tank is an IMS 10.7 gallon crossslinked polypropylene one. I have no knowledge of any special legal requirements of fuel tanks. That does not mean that there are none.

With that said, I have crossed both ways at the Mexican and Canadian boarders multiple times with no questions asked. I don't get stopped by police very often because I don't behave in a way that would make them want to stop me, so, I can't comment on that.

If there are regulations, I wonder about all the plastic lawnmower fuel jugs in the back of pickups and trunks of cars. Obviously manufacturers of those jugs are paying attention to the laws or they wouldn't have those difficult to use no spill nozzles on them.

 

Everybody who uses a plastic tank on the street finds that the police don't bother them.

They'll go after limo tints if they need something to do.