Old Mechanic trick for storing bolts when working on something, get yourself a piece of cardboard use a screw driver to poke holes in it smaller than your bolt diameter, force bolt into hole. You can even write on the cardboard little notes with arrow pointing to bolt to help identify them. Also if the bolt has enough threads showing you can leave things on it like grommets in the same order as taken off before pushing bolt into cardboard h Take off gas tank put a shorter bolt in radiator without going through gas tank. Replace gas tank now it will be over the bolt. Put pliers or vise grips on bolt shank, peek through gas tank hole and move bolt til bolt head lines up with gas tank hole. You can also use a marker and place a dot on the center of the bolt head to help alignment. Once aligned remove gas tank, remove shorter bolts, replace gas tank and use longer bolts through gas tank into radiator.
Dude! Where were you the day we tried to get this accomplished for two hours! Haha awesome man, thanks for the tip, that will come in super handy next time.
Looks like we both had a few problems with our tanks. I have the 3.9 Clarke on mine and had to shave some of the plastic off. I can't complain since I bought a $140 "scratch and dent" tank that has machine errors, works amazing. It definitely helps on long trips, I took my SM down to Georgia from here in Wisconsin, 2,200 miles in 3 days.
This was a challenge last time too. We started at 5:30pm and gave up at 11:30pm. We did get one of the IMS tanks or one of our DRZs. We had to cut out sections of the radiator guard as it was blocking the tank from seating right. on the second one, we cut a few centimeters off the black plastic spacers to get the angle right but still the nut AND bolt on left side stripped out. Now I have to drill that nut out or remove it all while being gentle with the radiator. If EVERYBODY has these problems, IMS should consider a redesign or tell people it won't work with radiator guards.
Take the tank off, realign the mount in the radiator with more more appropriate tools, ones in a manner that won't threaten the radiator, and then reassemble it. If you could get the radiator off to reach the mount, that would be safest, but a lot more work. Impatience often wrecks more things that damage from use does. Proper fixes require time and preparation. Are there any guards you could install to protect the wings of the tank when you drop it? The side the of the tank look a bit exposed. Adding 2 more gallons sure helps with range. Best of luck!
+DARIVS ARCHITECTVS Thanks for the advise man! I ended up letting Eddie figure it out. From what I can tell his solution was longer bolts and bigger washers trough the radiator guards and radiators themselves. Due to previous damage before I got the radiator guards there was no way to "properly" install it. This one took three guys and a little rigging to get accomplished. I can now get right about 200 miles worth of range. I haven't run it down to reserve yet.
ColoradoDualSport The fender washer/long bolt solution is actually stronger than using the original threads in the mount. Bent sheet metal is not your friend. I bet it was a finger jamming time getting the bolt in there! 200 miles range is just great for a light-midweight motorcycle. It takes 8 gallons of gas to get my BMW 320 miles.
Well done! CDS getting his hands dirty! I've ridden with several guys who have that larger tank. I'll have to see if I can track them down about your question at the end. They aren't TH-camrs though.
Ride AMAP We did a 100 mile ride on Sunday and near the the end I opened the tank just to see how much was left... Haha yep, half a tank + some! That was a great feeling. Yeah, ask them if they have any ideas. I'm using zip ties for the short term.
Just finished putting the IMS big-boy tank on my 2014 DRZ400. I too struggled with bolting the tank to the radiator supports and came in from the garage and found this video. Not much help from the video. I ended up loosening the radiators on each side from the frame and then bolting the tank to the loosened radiators. The radiators had larger bolts and went back together fairly easily. This is my third IMS tank and there is always a issue. The last tank I put on a 2000 DRZ400e and it leaked like a sieve at the petcock. I ended up filing the plastic on the tank until it was square and used a ton of permatex. I think IMS has since fixed this problem as this tank came with a nice little rubber gasket.
ladyeclectic Yep, we had the spacers as well. I ended up having the shop do it while they were looking at another issue. It's all bolted up properly now.
Looks like twice the fun! They told me to clean the inside of the clarke tank before I installed it... my goodness there was so much stuff in there! Enjoy the longer rides man!
ColoradoDualSport First ~ I enjoy your vids - thank you for sharing! Could you also share what the capacities are ~ Full to reserve and then reserve to empty? ( I too am in the market for a larger tank for my 400s. It looks like the 'tank' includes the entire radiator shroud area. But if that is true, then it would appear that at least 8 ounces of fuel will always be in the shroud portion lower than where that petcock is mounted on the main tank. (I am curious if IMS includes this fuel in their sizing?) BTW, for your mounting solution, you may be able to use washers/spacers to shift the radiator 's angle to line up better. Worst case -> put a bolt in the original hole to work as a base and then JB weld a nut to it exactly where you need it to be. Cheers!
yhiissuchbs You are correct about that fuel being below the petcock but if you should ever run out you can lay the bike down on it's left side and move the fuel over there from the right side it will get you home I have done this on one and it works. Take a look at the tank it's like a reserve gas storage on the right side.
Next time I recommend cleaning out tank with alcohol. It is less messy and dries quickly after you rinse it out. Gas is messy to use as a rinse. Good job on the new tank!!!
Mine also don't line up. I forced it to fit by pushing back on the radiator and pushing the tank to the front. Not looking forward to change my spark plug soon :) I met a guy that made a small little flat iron mount to mount it. I will try to get a photo next time I see him. I also had to cut off some of the spacers. The bolt would not reach the radiator with the original size.
Leon Gous Yep, I think that is exactly what i need to do. I got Hermit to look at it last weekend, so I'm sure he'll be coming up with a few ideas here soon. If you can get a pic of that guys setup, post it on the face book so I can take a look. Thanks man!
Thanks man! Yeah, it's a tough one. I don't mind if it looks a little bit ghetto, hell, it's an adventure bike! We'll figure something out this weekend.
I rocked that IMS tank on my old DRZ for years. I *never* quite felt comfortable with the "wings" of fuel surrounding my radiators, since that tends to be at the exact point of impact every time I fall over. Also, I had issues with the plastic spacers that shipped with the tank - they ended up melting against my radiator and I had to replace them with drilled out wooden dowels, which worked great. I have the Clarke 3.9 gallon tank on my current DRZ, and vastly prefer it. Either way, you'll love the extra capacity. I do a lot of long distance days as well, and not having to stop for fuel all the time is wonderful. What radiator guards are you using? They look great! PS: No clip needed on the vacuum hose. I've been on a DRZ since 2001, and have never had it come off.
The FLB Club Thanks for the info man! I really appreciate it. The rad guards are Devol and they are awesome. I also run their skid plate as well. I understand what you mean about the wings of fuel, but I'm not super worried. I tend to ride pretty conservatively most of the time and the plastic feels like it's pretty good quality. Wood isn't a bad idea... I'll see what I have on hand. You might be on to something.
elgroomez Which did you end up going with? I picked the IMS because safari is just insanely expensive. I still have yet to figure out where they put all of that money in the tank, but I have been grateful to be able to ride further and explore more. It's probably one of my top 3 favorite mods so far.
Ciao amico, posso chiederti un aiuto ? Io posseggo una DRZ400S. Ho trovato un IMS 4 galloni che proviene da un DRZ400E. Puoi dirmi se sono compatibili o se sono uguali ? Grazie mille
MrDuhfactor ColoradoDualSport need a bigger hammer... wait! he doesn't have one if he did he would of have use it to straighten the front bolt thing. a sledge hammer is ma favorite tool in ma tool box. lol
Agreed. Backing those, and the "radiator bolt" on the other side of the tank off a bit will give you some wiggle room which might be enough. Otherwise, take the time & take the tank off after taking some measurements regarding how far off the bolt is from being able to get through that hole (use masking or painter's tape to help with orientation/stable reference point if you need to). Once the tank is removed, remove the radiator guard and bend that radiator "ear/tab" back in to place based on the measurements you took and/or loosen the radiator mounting tabs to reposition the rad itself a bit. I wouldn't leave it unsolved for too long as the chaffing & rubbing from riding off road & not having a proper retaining bolt in there will cause a leak sooner or later. P.S. Xena looks nice in the buff, but the IMS tank makes her look badass!!!.
Nice thoughts guys, but I'm afraid the problem is bigger then just adjusting to fit. The nut that is pressed into the rad is gone on both sides. I think we are going to have to get creative with this one. I just wish I had known the importance of radiator guards when i first started riding off road. Guess I learned the hard way! Greg, I completely agree man! She looks super badass! Now the question is, to add stickers or leave it flat black.
ColoradoDualSport if you put stickers they will bubble up a bit. The gas actually fumes through the plastic gas tank, my man put punisher skull stickers on, and they bubbled but I think they still look good :)
ColoradoDualSport can you put a nylock nut where the nut is meant to be and use a longer bolt. I was the same as u, smashed up the radiator than thought hmm might be time to get some guards.
BlueGram 13 Thank you sir! For not knowing what the heck I was doing I tend to agree lol! The next project was wider foot pegs which are already done and to simple to really do a video on. We're on to suspension next, and I'm going to leave that to the pros.
BlueGram 13 Thank you sir! For not knowing what the heck I was doing I tend to agree lol! The next project was wider foot pegs which are already done and to simple to really do a video on. We're on to suspension next, and I'm going to leave that to the pros.
How far off from the hole is the bolt? I had to, with help from my dad, push the wings of the tank inwards, wasn't easy to do, but we got'er done. Then after using it for a while, it has "molded" to that form, and I can take it on and off on my own.
Adam W That may end up being what we have to do. The problem is that the rads are bent and don't line up properly any more. I'm going to have Hermit take a better look at it. If someone can come up with a solution, it's that guy.
had no idea what you looked like until today,,Klr got stolen,|Picking up a KLX400 with 600 kms on it next week, so was looking for mods for the DRZ/KLX, YAY CDS!
Well, I'm no engineer but do you really think it's necessary? Sounds like a lot of work for very little gain. Yes, the DRZ400S fuel system is vaccum operated hence why the petcock doesn't have an off setting and also why you can remove the fuel line without turning it "off".
ColoradoDualSport it's a vacuum acctavated petcock. they are common enough. no it doesn't need a hose clamp as its under vacuum it... it will stay secure as its sucked on there while the engine is running.
Hi CDS, congrats for the job, I have some questions and I 'll be happy if you can give me a light :) I just bought a tank like that and installed. Had the same problems you had and more..My tank is transparent and I see that fuel in a shroud area that could not be used. Do u suggest anything? a pump, another peacock? thanks
Hey man! The fuel system on the DRZ works via a vacuum so most of that fuel actually can be used even though it doesn't look like it. The bit that can't is what we call the secret second reserve. If you ever run out of fuel even after the regular reserve you can always lay your bike down on it's left side (side with the petcock) so that the fuel on the right side will flow over. That should get you an extra few miles to a gas station. Without any major modification that is about it. Hope that helps.
Nice! I was thinking about getting the Clark tank, but like this one. Although it is hard to believe they would make a tank for a specific bike and not drill the hole for the petcock big enough. How did it fit with the radiator guards, I have the unibiker guards (which I think are different than yours), but they pretty much look the same.
Eddie Marak Yeah, I was a bit perplexed as well. Maybe the E has a different petcock? It was really nothing hard to get it to fit, but I agree that it should be right from the factory. We didn't have enough hands to make it fit ourselves, so I paid Eddie a few bucks to get his guys to do it while she was in getting checked out a few weeks later. She fits great now! lol
ColoradoDualSport thanks! Have you had to take the tank off since then? The reason I ask is that I usually take trip up to Ouray once a year or so, when I do I have to re-jet for the altitude, just wondering if it is any more difficult to remove than the stock tank. From the install it looked like there was a lot of shifting, wiggling, etc... but not sure if that was just from the initial fit.
Have you ever had any issues with the tank touching the radiator guards? I have the exact same setup and I feel like the radiator guards touching the tank is bad but the tolerance is so tight and I don't want to get rid of them...
So I had put my tank on and had quite a bit of trouble lining everything up due to radiator damage much like yours. The tank was basically pushed up against the rad guards while sitting on the bike which didn't seem to be a huge issue but taking it on and off worried me because it was starting to get gouged on the inside by the guards. So I got some outdoor velcro I had laying around and took just the soft part of it and basically lined the sides and back sharp parts of the guards with it. Now it goes on nice and smooth, no gouging anymore, and the tank just rests against the soft velcro now. I would be interested to see if you've had any long term effects from it.
Both are jacked. The nuts that is pressed into the radiators are missing and even if they were there the angle is totally wrong. I'm thinking it's going to have to be a solution other then a bolt.
Well yeah, zip ties then! My tank doesn't even run those shroud bolts, but yours looked a little loose without them. Zip ties though man should be fine unless you want to try bending back those hangers.
I take it no one took a smoke break during the filming of this video with all the spills haha. Congrats on the new tank. Nicely done. So was the neighbor lady looking at you as if you lost your mind because I notice that you got a little flushed and tickled? Stay safe
All smoke breaks were taken over on Mr.Scott's porch a nice safe distance away. Ha! Nah, Mrs.Meg is Scotties wife and she knows all about CDS. She just smiled and said "sorry" for interrupting. I thought it was funny because it's always wicked quiet on our street except for the day that I decide to shoot a video in the garage. LOL that's the way it goes!
@@ColoradoDualSport when the diaphragm inside fails your dead in the water. Happened to my friend on a ride. Luckily he could coast down the trail almost to the truck.
I put the Acerbis 5.8 gal tank on my XR650 and have still not had to put that thing on reserve. haha Pull it all apart again and unbend the bent....hint buy a couple of locking jaw pliers.
Steve H Thanks man! We are over in Parker in the metro. I bet there is some awesome riding out there. Hermit told me there are some trails he wants to show me out that way.
Bballa11 Yep! $20 and someone else! LOL I think they ended up using after market bolts and a few guys to line everything up properly and push! Worth every penny to me.
Ahh I see, I just ordered an ims 4 gallon myself and my radiators got some decent bends in them so I guess I will try to fix them up a bit when tank arrives or ill just do zipties temporarily which will probably become permanent =P
Bballa11 Try your hardest to get the bots in. I was going through two sets of zip ties every ride. You may need to get some aftermarket bots and nuts, but it'll fit. Just be ready for drilling out the petcock a bit and you;ll be just fine.
Ok I will try to get it right don't want to be flying through zipties to much hassle hah. just waiting for the tank now, sadly s few more days, cant wait.
The Steel Horseman No use in crying over spilled Milk.... or 3/4 of a gallon of gas LOLOLOL!!!!! I smelled very manly for the next day and half. I think Mrs.Stacey liked it!
ColoradoDualSport No way man, my situation is a bit unstable right now, I don't even know if I'm going to have to leave colorado within the next few months. I might ask around how big bike and or novice friendly it is and prerun kokopelli. I know it's been done on KLRs and 990ADVs but "rose garden" might need bypassed. It would be a fun ride to do around the moab meet up. as part of a big 3-4 day grand loop ride or just by its self as a funner way to do the last leg of that drive to moab
Just finished putting the IMS big-boy tank on my 2014 DRZ400. I too struggled with bolting the tank to the radiator supports and came in from the garage and found this video. Not much help from the video. I ended up loosening the radiators on each side from the frame and then bolting the tank to the loosened radiators. The radiators had larger bolts and went back together fairly easily. This is my third IMS tank and there is always a issue. The last tank I put on a 2000 DRZ400e and it leaked like a sieve at the petcock. I ended up filing the plastic on the tank until it was square and used a ton of permatex. I think IMS has since fixed this problem as this tank came with a nice little rubber gasket.
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Old Mechanic trick for storing bolts when working on something, get yourself a piece of cardboard use a screw driver to poke holes in it smaller than your bolt diameter, force bolt into hole. You can even write on the cardboard little notes with arrow pointing to bolt to help identify them. Also if the bolt has enough threads showing you can leave things on it like grommets in the same order as taken off before pushing bolt into cardboard h
Take off gas tank put a shorter bolt in radiator without going through gas tank. Replace gas tank now it will be over the bolt. Put pliers or vise grips on bolt shank, peek through gas tank hole and move bolt til bolt head lines up with gas tank hole. You can also use a marker and place a dot on the center of the bolt head to help alignment. Once aligned remove gas tank, remove shorter bolts, replace gas tank and use longer bolts through gas tank into radiator.
Dude! Where were you the day we tried to get this accomplished for two hours! Haha awesome man, thanks for the tip, that will come in super handy next time.
Loosen the bolts under the seat and start all the bolts before you tighten them up.
Looks like we both had a few problems with our tanks. I have the 3.9 Clarke on mine and had to shave some of the plastic off. I can't complain since I bought a $140 "scratch and dent" tank that has machine errors, works amazing. It definitely helps on long trips, I took my SM down to Georgia from here in Wisconsin, 2,200 miles in 3 days.
For the rad bolt, thread one in the hole (tank off) and use it as leverage to bend back in position.
Yep
This was a challenge last time too. We started at 5:30pm and gave up at 11:30pm. We did get one of the IMS tanks or one of our DRZs. We had to cut out sections of the radiator guard as it was blocking the tank from seating right. on the second one, we cut a few centimeters off the black plastic spacers to get the angle right but still the nut AND bolt on left side stripped out. Now I have to drill that nut out or remove it all while being gentle with the radiator. If EVERYBODY has these problems, IMS should consider a redesign or tell people it won't work with radiator guards.
Thank you! Glad you went through that before me. My tank will be on the way soon and now I can see all the fun I will have LoL
DRZcoffeegirl Ride It's really not that bad. Just be ready to drill a little bit and have a funnel on hand and you'll be fine.
YES! Power tools check!
did you try loosening the back 2 bolts a little bit so that you can move the tank around
Well, my bike is 2002 and has an off setting. Hey, thank you so much for the tip!
Nice work. Until you get them front bolts figured out, I'm riding in front.
Fine with me. By CDS & HDV law that means I get all of your crash footage.
Take the tank off, realign the mount in the radiator with more more appropriate tools, ones in a manner that won't threaten the radiator, and then reassemble it. If you could get the radiator off to reach the mount, that would be safest, but a lot more work. Impatience often wrecks more things that damage from use does. Proper fixes require time and preparation. Are there any guards you could install to protect the wings of the tank when you drop it? The side the of the tank look a bit exposed. Adding 2 more gallons sure helps with range. Best of luck!
+DARIVS ARCHITECTVS Thanks for the advise man! I ended up letting Eddie figure it out. From what I can tell his solution was longer bolts and bigger washers trough the radiator guards and radiators themselves. Due to previous damage before I got the radiator guards there was no way to "properly" install it. This one took three guys and a little rigging to get accomplished. I can now get right about 200 miles worth of range. I haven't run it down to reserve yet.
ColoradoDualSport The fender washer/long bolt solution is actually stronger than using the original threads in the mount. Bent sheet metal is not your friend. I bet it was a finger jamming time getting the bolt in there! 200 miles range is just great for a light-midweight motorcycle. It takes 8 gallons of gas to get my BMW 320 miles.
Well done! CDS getting his hands dirty! I've ridden with several guys who have that larger tank. I'll have to see if I can track them down about your question at the end. They aren't TH-camrs though.
Ride AMAP We did a 100 mile ride on Sunday and near the the end I opened the tank just to see how much was left... Haha yep, half a tank + some! That was a great feeling. Yeah, ask them if they have any ideas. I'm using zip ties for the short term.
Just finished putting the IMS big-boy tank on my 2014 DRZ400. I too struggled with bolting the tank to the radiator supports and came in from the garage and found this video. Not much help from the video. I ended up loosening the radiators on each side from the frame and then bolting the tank to the loosened radiators. The radiators had larger bolts and went back together fairly easily. This is my third IMS tank and there is always a issue. The last tank I put on a 2000 DRZ400e and it leaked like a sieve at the petcock. I ended up filing the plastic on the tank until it was square and used a ton of permatex. I think IMS has since fixed this problem as this tank came with a nice little rubber gasket.
My IMS tank had a hard plastic spacer maybe 3/4" wide for either side, it changed the angle just enough that the longer bolts could get in easily.
ladyeclectic Yep, we had the spacers as well. I ended up having the shop do it while they were looking at another issue. It's all bolted up properly now.
Looks like twice the fun! They told me to clean the inside of the clarke tank before I installed it... my goodness there was so much stuff in there! Enjoy the longer rides man!
JgavemeaDRZ Exactly! Double to fun with no turning back! I'm excited to get out and see exactly how much mileage I do have.
Seems like a super nice tank! Good work!
It feels pretty high quality! Now if they just would drill the holes out right this would have been even simpler. Thanks man!
with the petcock tube so long, will you ever use all the fuel in the tank?
Crash Override The reserve is just a filter with no "pipe" so it will get all of the fuel in the bottom of the tank.
ColoradoDualSport First ~ I enjoy your vids - thank you for sharing!
Could you also share what the capacities are ~ Full to reserve and then reserve to empty? ( I too am in the market for a larger tank for my 400s.
It looks like the 'tank' includes the entire radiator shroud area. But if that is true, then it would appear that at least 8 ounces of fuel will always be in the shroud portion lower than where that petcock is mounted on the main tank. (I am curious if IMS includes this fuel in their sizing?)
BTW, for your mounting solution, you may be able to use washers/spacers to shift the radiator 's angle to line up better. Worst case -> put a bolt in the original hole to work as a base and then JB weld a nut to it exactly where you need it to be. Cheers!
yhiissuchbs You are correct about that fuel being below the petcock but if you should ever run out you can lay the bike down on it's left side and move the fuel over there from the right side it will get you home I have done this on one and it works. Take a look at the tank it's like a reserve gas storage on the right side.
Happy birthday CDS! I hope you can get the bolts figured out and enjoy the extra fuel.
Thanks man! I think we'll get it figured out this weekend. I can't wait to get out some long adventures and not have to turn back before I'm done!
Next time I recommend cleaning out tank with alcohol. It is less messy and dries quickly after you rinse it out. Gas is messy to use as a rinse. Good job on the new tank!!!
+M Roberts Good info! I didn't even think of that! Thank you!
Why didn't you take the seat off, loosen the back fuel tank bolts then tighten the side tank bolts.
Mine also don't line up. I forced it to fit by pushing back on the radiator and pushing the tank to the front. Not looking forward to change my spark plug soon :)
I met a guy that made a small little flat iron mount to mount it. I will try to get a photo next time I see him.
I also had to cut off some of the spacers. The bolt would not reach the radiator with the original size.
Leon Gous Yep, I think that is exactly what i need to do. I got Hermit to look at it last weekend, so I'm sure he'll be coming up with a few ideas here soon. If you can get a pic of that guys setup, post it on the face book so I can take a look. Thanks man!
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man I wish the Clark BossOffroad tanks were still available as that's the only tank that fits my bike...
looks nice and must be an advantage
only one hose connects tothat petcock?
Good video, not sure though about how to fix that. That's a tricky one cause you don't want to mess up the radiator. Hopefully someone else knows.
Thanks man! Yeah, it's a tough one. I don't mind if it looks a little bit ghetto, hell, it's an adventure bike! We'll figure something out this weekend.
I rocked that IMS tank on my old DRZ for years. I *never* quite felt comfortable with the "wings" of fuel surrounding my radiators, since that tends to be at the exact point of impact every time I fall over. Also, I had issues with the plastic spacers that shipped with the tank - they ended up melting against my radiator and I had to replace them with drilled out wooden dowels, which worked great.
I have the Clarke 3.9 gallon tank on my current DRZ, and vastly prefer it. Either way, you'll love the extra capacity. I do a lot of long distance days as well, and not having to stop for fuel all the time is wonderful.
What radiator guards are you using? They look great!
PS: No clip needed on the vacuum hose. I've been on a DRZ since 2001, and have never had it come off.
The FLB Club Thanks for the info man! I really appreciate it. The rad guards are Devol and they are awesome. I also run their skid plate as well. I understand what you mean about the wings of fuel, but I'm not super worried. I tend to ride pretty conservatively most of the time and the plastic feels like it's pretty good quality. Wood isn't a bad idea... I'll see what I have on hand. You might be on to something.
thanks for the vid. I'll be installing mine here shortly... maybe.. still undecided on safari or this IMS
elgroomez Which did you end up going with? I picked the IMS because safari is just insanely expensive. I still have yet to figure out where they put all of that money in the tank, but I have been grateful to be able to ride further and explore more. It's probably one of my top 3 favorite mods so far.
ColoradoDualSport I haven't decided yet. Did you end up not bolting the tank onto the radiator mounts?
Nice addition in having the big tank !!
K. Swaringen Heck yeah! I'm excited to not have to turn around!
Loosen the radiator. Fit the bolt, then tighten the radiator back up.
Wow need some stickers on that hunking black plastic tank
Ciao amico, posso chiederti un aiuto ? Io posseggo una DRZ400S. Ho trovato un IMS 4 galloni che proviene da un DRZ400E. Puoi dirmi se sono compatibili o se sono uguali ? Grazie mille
Just installed an Acerbis tank on my DRZ 400s and there isn't anything to attach the vacuum hose to. What's the best way to proceed here? Thanks guys
Awesome...love the bike
Nothing more hot that seeing CDS with a tool in his hand......Lol... well done my man... well done!!!
I did my best MrDuhfactor impression here! I now see why you like to have a dedicated camera man!
MrDuhfactor ColoradoDualSport need a bigger hammer... wait! he doesn't have one if he did he would of have use it to straighten the front bolt thing. a sledge hammer is ma favorite tool in ma tool box. lol
does it effect the turn radios ? does it change the way you sit on the bike? isn't to wide ?
Could try loosing Off the two rear bolts to make the tank move around a bit to get the two front to line up.
Agreed. Backing those, and the "radiator bolt" on the other side of the tank off a bit will give you some wiggle room which might be enough. Otherwise, take the time & take the tank off after taking some measurements regarding how far off the bolt is from being able to get through that hole (use masking or painter's tape to help with orientation/stable reference point if you need to). Once the tank is removed, remove the radiator guard and bend that radiator "ear/tab" back in to place based on the measurements you took and/or loosen the radiator mounting tabs to reposition the rad itself a bit. I wouldn't leave it unsolved for too long as the chaffing & rubbing from riding off road & not having a proper retaining bolt in there will cause a leak sooner or later.
P.S. Xena looks nice in the buff, but the IMS tank makes her look badass!!!.
Nice thoughts guys, but I'm afraid the problem is bigger then just adjusting to fit. The nut that is pressed into the rad is gone on both sides. I think we are going to have to get creative with this one. I just wish I had known the importance of radiator guards when i first started riding off road. Guess I learned the hard way! Greg, I completely agree man! She looks super badass! Now the question is, to add stickers or leave it flat black.
ColoradoDualSport if you put stickers they will bubble up a bit. The gas actually fumes through the plastic gas tank, my man put punisher skull stickers on, and they bubbled but I think they still look good :)
ColoradoDualSport can you put a nylock nut where the nut is meant to be and use a longer bolt. I was the same as u, smashed up the radiator than thought hmm might be time to get some guards.
I am impressed you did a good job the video was fine. What is the next project?
BlueGram 13 Thank you sir! For not knowing what the heck I was doing I tend to agree lol! The next project was wider foot pegs which are already done and to simple to really do a video on. We're on to suspension next, and I'm going to leave that to the pros.
BlueGram 13 Thank you sir! For not knowing what the heck I was doing I tend to agree lol! The next project was wider foot pegs which are already done and to simple to really do a video on. We're on to suspension next, and I'm going to leave that to the pros.
How far off from the hole is the bolt? I had to, with help from my dad, push the wings of the tank inwards, wasn't easy to do, but we got'er done. Then after using it for a while, it has "molded" to that form, and I can take it on and off on my own.
Adam W That may end up being what we have to do. The problem is that the rads are bent and don't line up properly any more. I'm going to have Hermit take a better look at it. If someone can come up with a solution, it's that guy.
had no idea what you looked like until today,,Klr got stolen,|Picking up a KLX400 with 600 kms on it next week, so was looking for mods for the DRZ/KLX, YAY CDS!
Man, that sucks about the KLR. I'm interested in hearing about the KLX though. From what I know, they are an exact carbon copy of the DRZ...true?
yep Will post it on instagram
If it's by vacuum, I could place a hose to the shroud area and it could work.. What do u think? I think it was by gravity only..
Well, I'm no engineer but do you really think it's necessary? Sounds like a lot of work for very little gain. Yes, the DRZ400S fuel system is vaccum operated hence why the petcock doesn't have an off setting and also why you can remove the fuel line without turning it "off".
ColoradoDualSport it's a vacuum acctavated petcock. they are common enough. no it doesn't need a hose clamp as its under vacuum it... it will stay secure as its sucked on there while the engine is running.
Nicely done
Bigger fuel tank means more fun :)
Thumbs up
My thoughts exactly! Thanks man!
i have the same tank in natural and i love it
***** Glad to hear it! I can't wait to get out on some nice long rides this summer.
Hi CDS, congrats for the job, I have some questions and I 'll be happy if you can give me a light :) I just bought a tank like that and installed. Had the same problems you had and more..My tank is transparent and I see that fuel in a shroud area that could not be used. Do u suggest anything? a pump, another peacock? thanks
Hey man! The fuel system on the DRZ works via a vacuum so most of that fuel actually can be used even though it doesn't look like it. The bit that can't is what we call the secret second reserve. If you ever run out of fuel even after the regular reserve you can always lay your bike down on it's left side (side with the petcock) so that the fuel on the right side will flow over. That should get you an extra few miles to a gas station. Without any major modification that is about it. Hope that helps.
Do you live in your garage? Lazy boy and a refrigerator. I'm definitely getting a bigger tank for my drz and a recliner for my garage.
Haha! No, but I'll be damned if I'm not comfortable while hanging out in there. 100% recommend the IMS 4 gal. Also don't forget the billet cap.
Nice! I was thinking about getting the Clark tank, but like this one. Although it is hard to believe they would make a tank for a specific bike and not drill the hole for the petcock big enough.
How did it fit with the radiator guards, I have the unibiker guards (which I think are different than yours), but they pretty much look the same.
Eddie Marak Yeah, I was a bit perplexed as well. Maybe the E has a different petcock? It was really nothing hard to get it to fit, but I agree that it should be right from the factory. We didn't have enough hands to make it fit ourselves, so I paid Eddie a few bucks to get his guys to do it while she was in getting checked out a few weeks later. She fits great now! lol
ColoradoDualSport thanks! Have you had to take the tank off since then? The reason I ask is that I usually take trip up to Ouray once a year or so, when I do I have to re-jet for the altitude, just wondering if it is any more difficult to remove than the stock tank. From the install it looked like there was a lot of shifting, wiggling, etc... but not sure if that was just from the initial fit.
Have you ever had any issues with the tank touching the radiator guards? I have the exact same setup and I feel like the radiator guards touching the tank is bad but the tolerance is so tight and I don't want to get rid of them...
Hm, I can't say that I've ever noticed a problem. I'll take a closer look when I get home tonight. I need to take Xena over for a bath anyway.
So I had put my tank on and had quite a bit of trouble lining everything up due to radiator damage much like yours. The tank was basically pushed up against the rad guards while sitting on the bike which didn't seem to be a huge issue but taking it on and off worried me because it was starting to get gouged on the inside by the guards. So I got some outdoor velcro I had laying around and took just the soft part of it and basically lined the sides and back sharp parts of the guards with it. Now it goes on nice and smooth, no gouging anymore, and the tank just rests against the soft velcro now. I would be interested to see if you've had any long term effects from it.
Does IMS provide the radiator bolts, because the OEM bolts definitely wouldn't reach.
Yes, all hardware is included.
+ColoradoDualSport awesome, thanks
So is it just the right side of the radiator hanger that won't line up with the tank and guard??
Both are jacked. The nuts that is pressed into the radiators are missing and even if they were there the angle is totally wrong. I'm thinking it's going to have to be a solution other then a bolt.
Well yeah, zip ties then! My tank doesn't even run those shroud bolts, but yours looked a little loose without them. Zip ties though man should be fine unless you want to try bending back those hangers.
I take it no one took a smoke break during the filming of this video with all the spills haha. Congrats on the new tank. Nicely done. So was the neighbor lady looking at you as if you lost your mind because I notice that you got a little flushed and tickled? Stay safe
All smoke breaks were taken over on Mr.Scott's porch a nice safe distance away. Ha! Nah, Mrs.Meg is Scotties wife and she knows all about CDS. She just smiled and said "sorry" for interrupting. I thought it was funny because it's always wicked quiet on our street except for the day that I decide to shoot a video in the garage. LOL that's the way it goes!
You should replace the fuel petcock with a manual one.
Why? The vacuum one works fine.
@@ColoradoDualSport when the diaphragm inside fails your dead in the water. Happened to my friend on a ride. Luckily he could coast down the trail almost to the truck.
Good to know. Thanks for the heads up.
Now its time for the sticker installment. need some stickers on the tank :-)
Ghost Rider ADV You know it brother! I'm going to break out my collection and start sizing up what I want to use.
I put the Acerbis 5.8 gal tank on my XR650 and have still not had to put that thing on reserve. haha
Pull it all apart again and unbend the bent....hint buy a couple of locking jaw pliers.
Britex3186 Awesome man! Yeah, I think that may be what has to happen in order to do it right. We'll see this weekend.
+Patrick Barber I don't really notice the weight difference much. Only when picking up after dropping it....only once.
Good Videos!! Where in Colorado do you live? I'm in Edwards near Vail and ride alot!
Steve H Thanks man! We are over in Parker in the metro. I bet there is some awesome riding out there. Hermit told me there are some trails he wants to show me out that way.
Did you ever solve the problem for mounting on the radiators?
Bballa11 Yep! $20 and someone else! LOL I think they ended up using after market bolts and a few guys to line everything up properly and push! Worth every penny to me.
Ahh I see, I just ordered an ims 4 gallon myself and my radiators got some decent bends in them so I guess I will try to fix them up a bit when tank arrives or ill just do zipties temporarily which will probably become permanent =P
Bballa11 Try your hardest to get the bots in. I was going through two sets of zip ties every ride. You may need to get some aftermarket bots and nuts, but it'll fit. Just be ready for drilling out the petcock a bit and you;ll be just fine.
Ok I will try to get it right don't want to be flying through zipties to much hassle hah. just waiting for the tank now, sadly s few more days, cant wait.
get longer screws or bolt
They have a metal fuel tank?
They do have a metal fuel tank. Well, she did. Now she doesn't.
The best way to learn is doing it yourself!
skutertrash1 My thoughts exactly! That's how I learned to build computers. Fortunately computers don't go 80mph on knobbies though LOL.
I love how you just laugh it off.
The Steel Horseman No use in crying over spilled Milk.... or 3/4 of a gallon of gas LOLOLOL!!!!! I smelled very manly for the next day and half. I think Mrs.Stacey liked it!
ColoradoDualSport www.trbimg.com/img-550dda24/turbine/la-dd-burger-king-perfume-20150321
sweet.
Time for some longer rides? cough*kokopelli*cough
I vote zipties, or a longer bolt with a spacer and nut and drill through
MM95 I think kokopelli sounds interesting. You trying to set something up?
ColoradoDualSport No way man, my situation is a bit unstable right now, I don't even know if I'm going to have to leave colorado within the next few months.
I might ask around how big bike and or novice friendly it is and prerun kokopelli. I know it's been done on KLRs and 990ADVs but "rose garden" might need bypassed. It would be a fun ride to do around the moab meet up. as part of a big 3-4 day grand loop ride or just by its self as a funner way to do the last leg of that drive to moab
CDS has piercings??? That's soo metal lol
Haha! You can thank my first serious girlfriend for that. But yeah, metal rules :-)
putting a hose clamp on the vacuum line is not a bad idea.
Even just a cable tie would probably do the job
I thought it was funny that it didn't have one on there. I wonder if it got lost at some point previously.
ColoradoDualSport Nope - it doesn't come with one.
I flushed mine out with water. wait till you see how much stuff comes out!
Tatmandu Well, I didn't flush it all that well. I hope it's ok......
does this added fuel weight change the way the bike balances like front heavy, back heavy etc.
Not at all. They did a great job of keeping the weight as low as possible and it's hardly even noticeable. I love that tank.
Ps. Spend the extra on a good cap. Worth every penny over the crap one that comes with it.
looks kinda looks darth vader'ish ,, good choice ,, you can rinse with 70 % rubbing alcohol ,, cheap , dries quick .
That convinced me to not buy that tank lol, what a PITA... Maybe the Clark 3.6 would be better, oh well...
Drz 400 E
"you're going to have to find a solution for that"..... Yeah stop crashing 🛵☁️☁️☁️☁️🥃😁
Just finished putting the IMS big-boy tank on my 2014 DRZ400. I too struggled with bolting the tank to the radiator supports and came in from the garage and found this video. Not much help from the video. I ended up loosening the radiators on each side from the frame and then bolting the tank to the loosened radiators. The radiators had larger bolts and went back together fairly easily. This is my third IMS tank and there is always a issue. The last tank I put on a 2000 DRZ400e and it leaked like a sieve at the petcock. I ended up filing the plastic on the tank until it was square and used a ton of permatex. I think IMS has since fixed this problem as this tank came with a nice little rubber gasket.