2006 TW200 meet '96 XT350 tank
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Thread: 2006 TW200 meet '96 XT350 tank

  1. #1
    Member m0t0-rydr's Avatar
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    2006 TW200 meet '96 XT350 tank

    So I had been reading (here) that the XT350 tank is an option for larger fuel capacity.
    After searching regularly for several months I saw one come up on eBay for $125 + shipping ($25).
    It was rust free and looked like this when received... (no gas cap)

    IMG_5278 sm.jpg

    Initially I wasn't concerned about the few little dings it had but as I looked at it on my table I decided to maybe touch it up here and there.

    Let's start with the decals...
    IMG_5284 sm.jpg

    Maybe touch up that ding. Gotta get it to metal first though. Right?
    IMG_5286 sm.jpg

    OK, so I guess I may as well strip the entire tank. By hand. Then bondo.
    IMG_5295 sm.jpg

    I was planning to use the TW in Death Valley end of March so time was running out.
    I wouldn't be able to do the painting myself.
    At this point I was getting frantic and was just gonna spray it with truck bed liner.
    Last edited by m0t0-rydr; 04-01-2018 at 11:12 PM.
    littletommy, ejfranz, Fred and 2 others like this.
    '06 TW Moose skid, Protaper ATV Mid, Acerbis handguards, IRC pegs, folding shifter, Hella +30% bulb. USB/voltmeter, cig lighter socket, tachometer. Oil cooler, .70Kg springs & emulators, 19Kg (red) shock spring, Happy Trails Racks, Roto-pak fuel mount, tool tubes, Shinko 5" front, High front fender.
    ...and more. It's, it's like an addiction!

    Other moto's- 88 R100GS, 06 450EXC plated, 06 950 Adventure S, 96 XR600R plated, 03 Zuma 50, 76 ST90, 74 Z1, 53 Harley Hummer.

  2. #2
    Member m0t0-rydr's Avatar
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    After discussing my dilemma with a co-worker a plan was established.
    I handed the tank over to a co-workers painting instructor who applied the primer, base and clear in urethane.
    Came out pretty nice.

    IMG_5314 sm.jpg

    IMG_5315 sm.jpg

    Here's how it was set up after my return from DV...
    3.2 gallons in the XT tank and another gallon in the rotopak... range!

    IMG_5443 sm.jpg

    IMG_5451 sm.jpg

    Only the slightest wrinkle in the seat fabric from the bend for the larger tank.
    IMG_5453 sm.jpg

    I did clip some of the under seat plastic pieces but they key was using my heat gun to heat and bend the seat pan to the angle I needed.
    I did make the extended bracket for the longer XT tank just like mentioned in the XT350 tank install thread here on the forum.

    I'm hoping for a range of near 200 miles. (w/o rotopax)
    Time (in the saddle) will tell.

    edit to add...

    I did have to add Zeta bar risers to allow the bars to go lock to lock w/o hitting the tank.
    Last edited by m0t0-rydr; 04-01-2018 at 11:21 PM.
    '06 TW Moose skid, Protaper ATV Mid, Acerbis handguards, IRC pegs, folding shifter, Hella +30% bulb. USB/voltmeter, cig lighter socket, tachometer. Oil cooler, .70Kg springs & emulators, 19Kg (red) shock spring, Happy Trails Racks, Roto-pak fuel mount, tool tubes, Shinko 5" front, High front fender.
    ...and more. It's, it's like an addiction!

    Other moto's- 88 R100GS, 06 450EXC plated, 06 950 Adventure S, 96 XR600R plated, 03 Zuma 50, 76 ST90, 74 Z1, 53 Harley Hummer.

  3. #3
    Senior Member Miaugi's Avatar
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    Looks great! Good work!
    littletommy likes this.
    Hidden Content Sold...Oct 2018......'01 F650GS

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  5. #4
    Senior Member Peterb's Avatar
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    Looking good! I love my XT tank.
    littletommy likes this.

  6. #5
    Senior Member Spawner's Avatar
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    Ive got that exact tank sitting on my workbench... and the exact year/color tw... Another project to get started... Nice work!!!
    littletommy likes this.

  7. #6
    Senior Member Gulfrider's Avatar
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    Looks great
    littletommy likes this.
    2005 TW200
    2007 Sportster 1200

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