Bigger gas tank for 2003 450EXC

Discussion in 'Thumpers' started by James Adams, May 10, 2012.

  1. James Adams

    James Adams non impediti ratione cogitationis

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    I'm having difficulty finding any large fuel tank options for my '03 450 EXC except for the $afari tank, which also requires a seat change. Are there any other options that fit with minor modifications?
    #1
  2. tHEtREV

    tHEtREV Captain Awesome... tEAM iDIOT.

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    I though the 03 would accept the 04 to 07 tanks with no midification.

    I know you need an 03 seat to fit a 03 to 07 tank on a pre 03 EXC.

    I'm running a tank was fitted to an 06 EXC on my 00 200, all I had to do was fit the 03 seat.

    Edit, I just did a part number search for the 03 450 exc tank (5900701350044) and it shows the following models use the same part...
    (remembering that this list only includes bikes with this part number and wont include thos that use a different part number because the tank is a different colour).
    <table><tbody><tr id="213573/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">450 EXC</td><td class="partCell partClickCell">2005</td><td class="partCell partClickCell">
    </td></tr><tr id="214946/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">250 EXC RACING</td><td class="partCell partClickCell">2006</td><td class="partCell partClickCell">
    </td></tr><tr id="213413/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">250 EXC RACING</td><td class="partCell partClickCell">2005</td><td class="partCell partClickCell">
    </td></tr><tr id="212434/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">525 EXC</td><td class="partCell partClickCell">2004</td><td class="partCell partClickCell">
    </td></tr><tr id="211941/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">250 EXC RACING</td><td class="partCell partClickCell">2004</td><td class="partCell partClickCell">
    </td></tr><tr id="211048/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">450 EXC</td><td class="partCell partClickCell">2003</td><td class="partCell partClickCell">
    </td></tr><tr id="210886/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">250 EXC RACING</td><td class="partCell partClickCell">2003</td><td class="partCell partClickCell">
    </td></tr><tr id="213836/M.1647264"><td class="partCell partClickCell selected">KTM</td><td class="partCell partClickCell selected">525 EXC</td><td class="partCell partClickCell selected">2005</td><td class="partCell partClickCell selected">
    </td></tr><tr id="211288/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">525 EXC</td><td class="partCell partClickCell">2003</td><td class="partCell partClickCell">
    </td></tr><tr id="215356/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">525 EXC</td><td class="partCell partClickCell">2006</td><td class="partCell partClickCell">
    </td></tr><tr id="215068/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">450 EXC</td><td class="partCell partClickCell">2006</td><td class="partCell partClickCell">
    </td></tr><tr id="212136/M.1647264"><td class="partCell partClickCell">KTM</td><td class="partCell partClickCell">450 EXC</td><td class="partCell partClickCell">2004</td><td class="partCell partClickCell">
    </td></tr></tbody></table>
    #2
  3. Off the grid

    Off the grid Unsmooth Operator

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    I'm pretty sure there are differences between 02-07. My 05 Clarke tank did not fit on my buddies 02 450.

    To answer your question, Clarke makes a good tank, but were I to do it again I would get the KTM hardparts tank, it's the same size (3.1gallons) but looks fkn cool. :D They extend your range to about 120-140miles per tank depending on your right hand.

    *Edit as far as larger tanks I think the supply is limited. There are 1gal auxiliary tanks you can buy though.
    #3
  4. James Adams

    James Adams non impediti ratione cogitationis

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    After consulting with a few other folks, I have a 6.6-gallon Acerbis on the way. It sounds as though it will fit well enough for my use.
    #4
  5. tHEtREV

    tHEtREV Captain Awesome... tEAM iDIOT.

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    Any idea what the problem was?

    I know the seat doesn't fit the tank unless you trim the front of it, but I thought that was all.
    #5
  6. Off the grid

    Off the grid Unsmooth Operator

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    That buzzing in your earhole, NorCal.
    I don't remember unfortunately. Might be the location of the tank mounting stem.
    #6
  7. cedric

    cedric Been here awhile

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    The dual headers and the kickstarter are different and that may be the issue. I had to change my kicker to get an '03 stock tank to fit my '02.
    #7
  8. James Adams

    James Adams non impediti ratione cogitationis

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    There's a small tab on the dual headers that interferes with the support brace for the 6.6-gal Acerbis tank. I think I can clearance :evil it with a hammer and vise but I have other work to do on the bike first. It does look like some minor seat modification will also be required.
    #8
  9. pcvance

    pcvance Walk Verplank

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    Here's my 04' EXC fitted with an 05' XC 3.6 gallon tank and seat, no fit up issues. The stock EXC seat will fit but with gap issues along the tank and airbox. I also added a Baja designs 1.1 rear tank for a total of 4.7 gallons. The bike will now go 200+ miles, plenty of range. The 6.6 Acerbis seems like overkill. FYI, the tank and seat cost me $150.00 on CL, they were both like new. The only problem is my KTM hard parts radiator guards don't fit, but the tank itself offers decent protection for the radiators.
    [​IMG]
    #9
  10. James Adams

    James Adams non impediti ratione cogitationis

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    Just a quick update. I've ordered an aftermarket header for my '03 450EXC that should allow me to install the lower tank braces on the big Acerbis tank. We'll see...
    #10
  11. rattlinjack

    rattlinjack Adventurer

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    Gday James!
    Very interested in the outcome here..
    I'm going through the same search, here in Australia, Bigger tank needed, no luck so far..

    So, what sort of after market header have you ordered? "Mines damaged" so I need a new one:cry
    #11
  12. James Adams

    James Adams non impediti ratione cogitationis

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    It's an FMF titanium PowerBomb header, it turned up on eBay and the price was very right.
    #12
  13. rattlinjack

    rattlinjack Adventurer

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    Good stuff! Is it a 2003 one? or do later models fit?
    #13
  14. Ellusivebull

    Ellusivebull n00b

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    I have an 03 300 exc and would also like to know how it turns out. I have been trying to figure out if I can order the 6.6 and make it work. What was the seat issue that you had and how did you overcome it? Any pictures of a finished product? Thanks

    Joey
    #14
  15. tHEtREV

    tHEtREV Captain Awesome... tEAM iDIOT.

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    I was playing around with my 6.6 when I got it and put it on my 00 200exc for a test fit.

    I had an 03 seat on it and was using a later model tank.

    The tank fit OK, but the tank braces that come with the kit wouldn't work, you would have to make new ones, and the seat mounting tabs wouldn't line up with the mounting nuts, they were a centimeter or two to far back.

    I didn't try to fit it properly, it was just a test fit and I have since sold the 200.

    There was a guy on this thread that fitted one to his 250sx so it must be possible.
    #15
  16. ropeman@ADV

    ropeman@ADV Been here awhile

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  17. Off the grid

    Off the grid Unsmooth Operator

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    That buzzing in your earhole, NorCal.
    Clarke makes a great product, and the one I bought had a leak, so they shipped a new one out without question or even wanting the old one back....and in a diff color from the original one to boot! (I ordered orange, but really wanted translucent)

    But if I had to do it again, I would go with the KTM hardparts tank like the one on the 525 above picture. It just looks cleaner and holds a bit more.
    #17
  18. BenYork

    BenYork Adventurer

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    So, did that 6.6 acerbis fit on the 03 450exc?
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  19. Meriden

    Meriden Yea whatever

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    James, I may be selling a 1.1 gallon Baja Designs in orange in the next couple of weeks. It all depends on if I can get the black in on time. When do you need it? I'll be in Cowtown for Christmas so a delivery may be possible.
    #19
  20. MotoFlicka

    MotoFlicka Adventurer

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    What was the outcome of all of this? :ear I need to do the same. Bigger tank on 2003, KTM 450EXC. Any suggestions as to the less hassle of a bigger tank appreciated. The Clarke site looks good but would be good to hear if results were good. http://justgastanks.com/product_info.php?products_id=460

    Thanks!
    #20