In order to convert my XR250L to a somewhat presentable streetbike, the gast tank needed to be swapped. I tried taking measurements and looking for compatible gas tanks online, but its impossible to find specs of the shapes of gas tanks. I wasn’t about to spend $500 on a custom made sucker, either.
I wound up finding the gas tank from an 1980 XR200 hanging on a wall that looked pretty neat. I test-fitted it to my bike and it looked like it would fit with some finagling. The important thing is to make sure the tunnel is deep enough, there is a way to mount the front, and a way to mount the rear. Heh, mount the rear. I gave it a shot.
Tunnel
The tunnel in the XR200 tank is way narrower than the XR250 frame. I took a ball peen hammer and banged the shit out of it until it fit. That, ah, pretty much did it. The tank sits at an appropriate height.
Front
To fit the front, I used a hole that was already in the frame (stock?), relocated and trimmed the robber grommets that the stock tank grips to. A few washers made spacers to get the width correct.
Rear
The tabs on the XR200 tank were banging against the frame and the tank wasn’t sitting right. I cut the tabs, drilled two holes on each side, and the tank is being secured by safety wire (and the stock seat, which I’m gonna modify).
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