6.6 gallon tank on a KTM 250 2 stroke

Here's the deal, I have an Acerbis 6.6 gallon tank that I bought for my 525, but I want to put it on my 2004 250 exc for the tour of Idaho this summer (I could use the 525 but I enjoy riding the 250 so much more)
I dropped the tank on the 250 and it fits perfectly except in one crucial spot where it touches the expansion chamber :eek1 The chamber I have on there is the FMF Gnarly, I've seen pics of other KTM 2 strokes fitted with this tank and they didn't have this issue, so it may be a pipe thing, but in lieu of buying a new expansion chamber I was wondering if putting some heat shielding between the tank and the pipe would work? Also, can this tank be heated and re-shaped?

here are a few pics of the issue:





any input appreciated

Count me as interested in what you find out. I ruled out a two stroke because of the lack of range. It would be nice to have an alternative.

This guy has one on his SX http://advrider.com/forums/showthread.php?t=624747&page=6

and there was a guy with a 300 who had one as well

Why not mount a couple 1/2" spacers between the tank and frame?

Easy, non permanent, and it should solve the problem...

You can't get a bit of rotation out of the expansion chamber mounts? My 200 can be varied some.

just put a "performance" dent into the pipe in that area.

Agreed. That's the biggest part of the pipe and it probably won't make any difference.

I have a few performance dents already, guess 1 more won't hurt. I think I'll try shifting it around and look for other options first though.

oh, and I tried spacers, didn't work.

I'm doing T1 on my 300 xc this year. 2 stroke fever.


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this.

Get out the

B F H

Just tale a heat gun and mold the tank inward in that location about 1/2'. I did it before to make a fan fit on one, it's pretty easy, use a blunt piece of wood to push it in and hold it in as you pour some cool water on the area.

I think I'll try ridefreaks solution first and keep the bfh to the pipe solution as a back up. Thanks for the input.

For those who are interested, I used a heat gun and carefully molded the tank, I also adjusted the fit of the pipe a bit and now have about 3/4 of an inch clearance. I will probabe add some heat shielding to the pipe as well but it looks like it's good to go, I'll just have to chack it if I dump the bike.

thanks for the input, I'll post pics when I get it all mounted and finalized.

Glad it worked out BTW, 2T pipes don't get near as hot as their 4T brethren.

I'm going to re-animate this old thread rather than starting a new one.

I am attempting to fit the same tank onto a 2000 250 2T EXC. I had the tank fitted to a 2001 520 EXC for a while with no issues, it is out of action for a while, so I am moving all the good gear over to the smoker.

The pipe doesn't interfere, but I appear to have two other fitment issues;
1. No way are the standard support brackets that bolt onto the front engine mount going to clear the pipe
2. Clearance around back of radiators seems a bit tight, and I can't seem to get it seated, so it still moves around a bit.

@gameyogi did you use the front supports, or just the single bolt in the frame spine, from your pictures I don't see the supports.

I can't help you with the 2st question, but I'm trying to install the 6.6 gal tank on my 2000 520..........so what seat do you guys use and do you have a part number?

Thanks

Interesting old thread.

I was looking at putting a larger tank on my ktm 300exc. I wanted a 100 mile range. It looks like ims makes a 4 gallon tank. I think that will be relatively safe.

A 6+ gallon would be overkill for me...