Adventure Trail Bike Forum

Just posted the following up on the xr400 Thread /section on ADV.
Before reading on this is a common problem with these tanks, as the one currently fitted will testify by way of the witness marks on it from the previous owners clamps.
The general consensus was to try and get maximum adjustment from the fitting hardware, as well as making sure that it was sitting correctly on the frame spine; both were done before undertaking the following.

IMS Tank being hit by triple clamps
[QUOTE=mark1150;23924972]Hi Guy's
Just fitted an IMS 17ltr tank to the XR, but it's being hit by the triple clamps on full lock.
Has anyone got any experience with these?
I was thinking about maybe drilling and tapping the bottom stops (bottom triple clamp) and fitting a bolt to act as an adjustable steering stop.
Is this a good idea, or are there any pitfalls that you know of.
Thanks in advance.

I wrote this a week or so ago, and despite following the valuable advice that I was given not only were the triple clamps hitting on full lock, so to were the hand guard brackets, despite cutting them back nearest to the tank and filing them round and smooth.
So plan B was instigated I.E. making adjustable steering stops.


As you probably know this the how the bottom clamp came out of the factory.


So out with the drill, drilled it out to 4.5mm, (M5) tap size and threaded the hole.


I fitted an M5 Allen bolt with the rubber from the OE skid plate (the tubular alloy one)


This is the view from the top as it is now.... bags of room for both the triple clamps and the hand guard clamps.

I must say that I'm a little less paranoid about something punching a hole through the tank now.

While I was at it I had an ongoing problem with the kickstarter; whereby when it was folded into the closed position it didn't click and had on occasion folded itself out when pushing over rough trails.
You'll see my interim solution in the following pic, 2 industrial sized zip ties, cut down to make keepers.
However while I had the drill out I stripped out the mechanism, and slightly rebated the hole where the ball bearing locks into, plus fitted a couple of tiny washers behind the ball bearing spring.
Job done and she now clicks shut, although as belt and braces I'm inclined to keep the zip ties.


So all in all a productive Sunday.

Nice one mate, the accident damaged the lock stop when turning left on the gs. They are mounted under the top yoke as no bottom one as such on the GS, it put a 3mm deep dent in it, which is not a lot I hear you say but when it is mounted right next to the column by the time it transfers to the end of the bars its over 30mm. Fortunately the new screen is narrower than stock but I have fitted a touratech lockstep just in case.

Thanks mate, just edited the post giving a bit of further background information about these tanks and how they fit.
Yep I can identify with the 3mm thing, as it only took the depth of a 5mm cap head plus a couple of mm of rubber to give me all of that clearance up top.

BTW is your TT stop the same as my TT Hard part rubber stops (rubber bullet shaped thingy) that I had on the 1150?
If so and you manage to lose one they replace them FOC inc P+P.

The same as the one I had on the red 1200 mate.

Brilliant fix TP! Looks good!

In theory , should you drop the bike hard, the rubber will absorb impact and prevent ( or help to) the bars bending


Sent from my iPod touch using Tapatalk

Nicely done TP, a cheap fix with good results. Thanks for posting

Thanks all,
I also araldited in a couple of solid rubber inserts to bolster up the rubbers fitted, and cover up the allen bolt head.
Also forgot to mention an add on to the original post, that I've also successfully fitted the pet cock repair kit from the USA.
Now the tap works in the off position with no leakage.