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I don't really know what Honda did to the XRL in the late nineties, but the frame seems to have got a little wider at the top of the rear shock. as a consequence, the 40 litre tank slightly fouls the frame on later models. several of us had the tank modified on 2003/04 models to give enough clearance - this involved heating the thermoset plastic hot enough to deform, but not burn it. I don't recommend trying this yourself!
I gather you should be fine with tolerances on the 22 litre tank.
Cheers for your input folks.
I've now got the tank mounted, and sufficiently unashamed with the job I did, I thought I'd have a go at posting some photos.
The mounting kit that comes with the tank is laughably low quality, and the intended mount setup is shocking.
I went for a different approach, and time will tell if it was a good idea or not.
Photos should explain, but here's what I did...
1-Used 4 1/2" angle grinder to remove elephant ears from frame
2-Cut, punched and folded 3mm stainless plate to mimic acerbis provided plate, but posn tank 15mm further back to prevent foul of triple clamps on tank
3-Cut replacement indicator brackets from Ali angle to prevent indicators fouling tank
4-Cut about 5mm from each of the noggins that hold the rubber bungs under the tank (as mentioned above, tank is a ver tight fit over these)
5-Machined 2 (handed) ali blocks that fit round frame, where ears used to be, allowing oil tube and elec cable to pass through
6-Templated relationship between 3 tapped holes in each side of the tank, and the 8.5mm holes in my clamps.
7-Cut this template into 4mm Ali sheet
8-Bolt this lot together with a bit if old inner tube to cushion where required, and a few spacers round the clamp
9-Drill a couple of holes in the RH plate, to re-locate the reg/rect.
I think that was about it, if anyone wants more info, I'd be more than happy to help.
I've got a couple of the rear tank brackets if anyone wants, and I can make up more ali clamp blocks if there's a need.
I've got a list of future mods as long as my arm, but next to tick off is a new exhaust, and jet kit, that I'm hoping may give the old girl a bit more poke.
Stock, this bike's got to be the most underpowered 600cc+ bike in production!?
Maybe accounts for the reliability..
After this, looking forward to custom pannier and rack fabrication. Likely to be a major undertaking I think.
What did you do to yours? Any suggestions or advice?
Were you carrying much weight on yours?
Location: Buenos Aires,City of good sex,mate and asado!
Lots of stuff but not rejetting yet????
This is a thing still to do! I will get those dyna jets 55-158.
On the bike itseld did little.Still using paper filter and stock exhaust.Don´t like noisy bikes to much.Just removed the spar arrester and driller a few holes more to it.Cheap and more flow.
The pannier rack is self made(tesch type) but i could imagine today buying some round pipe type one and adapt it.
Look for a good rack on the back.
Replaced the original brake hoses with stainless steel ones.
Custom made bush plate.
40 liters tank and reshape the seat.(done last year)
Ok man where do you plan to travel?
BaronBolton, I hope I am not too late. I just recieved the same tank for my 07' XR650L. How is your setup working out for you? Do you have any detailed pictures showing your setup? I like my new tank but do not care for the hardware that was provided with the tank. Is there any chance of you making up another insatll kit?
Thank you, Marco.
KH- I`m now finally on the road, after spending probaly over a hundred hours preparing the bike and making stuff for it.
I`ve ridden the 4500 miles from my home in the UK to İstanbul, and I`m just preparing for the big adventure through the 'Stans' and accross Russia dn Mongolia.
Thanks for your help with the rack a few months back, if you`ve got a minute have a chufty at the site I`m working on. There`s info on there about most of the work I`ve done on the bike, and my route etc..
getafterit- I have actually mounted two Acerbis tanks on two different XR650L`s. The last XRL I had, I sold to a good friend of mine (charlotte_goose) for a crazy knock-down price ;-) (you listening Char?)
I now have a slightly newer one, and tried a different approach.
I am just working on a website about my current trip, and how I prepared for it. There`s a bit on tank mounting, so maybe have a look there?
I would say that both approaches have their merits. The first one shown above is good in that it requires no welding. Both feel absolutely rock solid. I think the bike could probably be lifted by the tank with no damage.
Though it`s the vıbration that`s probably the bigger threat.
I`ll update you in a year when I`ve hopefully crossed Mongolia and Siberia!
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