Installing a Clarke XT225 tank
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Thread: Installing a Clarke XT225 tank

  1. #1
    Senior Member Guitarman's Avatar
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    Here I'll show you how I Installed my Clarke XT225 tank.



    First I want to say thanks to two members here :



    lzrdbrth, who had the great idea to start a group buy at justgastanks.com



    Darnold87 who helped me in my quest with his useful thread about his XT225 tank installement.



    Thank you guys! ;-)





    Here is how I did mine



    You will need :



    1 XT225 tank

    2 hockey pucks

    1 backsaw

    1 tin snip

    1 small bracket that came with your new tank

    1 top bracket from your stock tank (zinc coloured one)

    3 zip ties

    1 10mm bolt and nut

    1 drill and a 1/4 bit

    1 piece of rubber (about a square inch or so)

    Something to sand



    1. Take your hockey pucks and mark them so they fit in the cavities of the tank







    2. Take your backsaw and cut the pucks (I used a C-Clamp to hold them in place will sawing)







    3. Cut them on the side so they match the thickness of the stock TW200 pucks







    4. Dill one hole in each puck (place a stock puck on top of your custom puck to help you)







    5. Sand the opposite side of the puck and give it a round shape like the stock ones



    rmcglad55, Yellow CR and Gerry like this.

  2. #2
    Senior Member Guitarman's Avatar
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    6. Take one of your stock pucks, a small bracket that came with your new tank and screw them just like that with the stock tank bolt







    7. Add a layer of foam that came with your new tank. I used a zip tie to hold it in place. I did this cause my tests revealed that there was something scratching the tank in this area.







    8. Put your new tank in place and screw it tight. I placed a small piece of rubber between the two aluminum brackets and put the stock zinc bracket in top.







    9. Cut a small notch in your seat like that.



    Yellow CR and Gerry like this.

  3. #3
    Senior Member Guitarman's Avatar
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    10. Cut your side covers so they fit and compliment your new installation (I used tin snip). Drill two small holes, one on each covers, where they meet the frame and zip tie them in place so they won't fly while cruising on the highway (thank you lzrdbrth for the suggestion, I just red your post this morning about your experience)









    11. Install your stock petcock. It will fit, but it's a tight fit.







    12. Put your seat back on and take care to slip the tab under your new bracket









    Voila! You can now enjoy your ride again without having to fuel four times a day ;-)



    If you want your installation to be perfect, you will need handlebar risers or your stock bar will hit the tank at full turn.



    I insist on risers because I first installed a Protaper ATV High bar and had the same problem, the base of the bars (where it bolt to the triple tree) would hit the tank. I was lucky I had some risers on another bike that I could use. Problem solved.



    I will try the setup as it is now and see if I like it. The bar sit pretty high and I'm a bit worried about the cables I had to reroute. They seem ok but I'll definitely keep a good eye on them in search of any premature wear. There is no binding as I call tell, but they are surely tighter than they were before.



    I'll keep you updated on that.



    ;-)
    Yellow CR and Gerry like this.

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  5. #4
    Senior Member r80rt's Avatar
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    That looks great, the hocky pucks a good idea. Well done!
    Only a fool would attempt it, and God help me, I am that fool!

  6. #5
    Member Kf6rqb's Avatar
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    Good job on the photos ,the tank looks like a good fit, how many gallons is it ? The puck is a good idea! Good Luck!
    Dave A. Smith

  7. #6
    Member JKWheelin's Avatar
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    Excellent write up! Thanks for posting.
    2011 TW200 Hidden Content

  8. #7
    Senior Member PJungnitsch's Avatar
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    Nice job! and helpful writeup. I might try that hockey puck idea, they are cheap and easy to work with. I've made do with the stock pucks for the last two years, they caused no problems but are definitely looser than stock.



    Am thinking of offsetting the hole to lift the tank front up higher to access more fuel.

  9. #8
    Senior Member Guitarman's Avatar
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    Thank you guys!



    The tank can hold 4.1 gal. I say hold cause the available capacity is reduced by the forward protuberances being lower than the petcock. Needless to say that a relatively good quantity of gas seems to be "stuck" on that right pocket (you'll have to tilt the bike left if you get short on gas). The XT350 tank seems to have a better design in terms of gas availability.



    It might be a good idea to offset the hole in the puck, but I feel it would worsen the "handlebar hitting the tank" problem...

  10. #9
    Senior Member admiral's Avatar
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    Great job Guitarman. This is surely going to help the forum. Thanks for your contribution.
    Last edited by admiral; 02-25-2016 at 10:34 AM.


  11. #10
    Senior Member Guitarman's Avatar
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    You are welcome ;-)

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