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After much thought and consideration, I decided it was time for more fuel capacity. I've done some overnight adventures and have glided into a few gas stations running on fumes... And not having to pack around a Koplin or similar fuel can sounded nice, especially for daily summer riding to work... So anyway, here goes...

My buddy Bagwell (fellow TW200forum member) recently got the Clarke TW200 2.7 gallon tank and it looks and works great. But I was feeling 'Froggy' and decided to jump for the XT225 4.1gallon. A couple other TW200forum members on here have done it and I liked how they looked, and definitely liked their capacity!

I got mine through www.justgastanks.com and with the "ADVrider" discount code, it was at my door in about 10 days for $193.

Initial mock up looked good but I instantly knew it wouldn't be super easy. After a day of pondering, I came up with a plan and it worked great. The tank comes with 3 aluminum brackets to relocate the horn and plastic side pieces for the XT225. Well, I used the horn relocation bracket (drilled a 2nd hole to move the tank forward a 1/4" or so) and bolted it on top of a rubber bushing I had in my assorted goodies and mounted the stock rubber tank mount on top of that and it worked perfect. The tank has an aluminum bracket that bolts to it. All I had to do here was slightly increase the angle of this bend. Super easy. The front pucks that the tank slides onto were about 1.5 inches ahead of seating in the tank's slots. It actually worked but felt loose and seemed risky. For this, I knew I needed to make oblong pucks that went all the way into the tank's slots. For each side I used a stock puck and added another rubber bushing I had and taped them together using that self-vulcanizing emergency fix-it tape that some folks keep in their emergency tools and such. Anyway, it easily made the oblong pucks solid and very functional. And that's it. This setup has the tank a solid 1" or more above the engine. Hopefully the tank won't settle more than that over time. I got a new TW200 petcock, which runs about $21. The seat conformed well and required no mods to fit. Right side plastic works as is, but could be trimmed a tiny bit. Left side plastic still needs to be trimmed as the petcock is actually a little behind it. Will update this thread once I get that done. Lower brake cable guide (on triple tree) has to be flipped around and mounted forward, rather than backwards.

So far I have ridden 50 miles of road, gravel, and trails... plus countless wheelie attempts and everything is solid.



Other doodads include:

Small dual filament front marker / turn signals to match my rear ones (Amazon.com)

New foam air filter element.

Checked the valves - looked great (~4000 miles on the odometer).

Cam Chain Adjuster - was waaaay loose. Set to factory spec (per FSM) and my engine sounds amazing now!... Even feels smoother / stronger.

High-Fender setup - used 1/4" Allthread and bent it to clamp over the lower triple tree. Easy setup but found stock fender is too small in wet / muddy conditions.
Lots of over-spray to your chest / face. Going to try a YZ250 front fender next. If that's ugly, I'll go back to a low-fender stock setup...

LED Tail Light / Plate Mod - Light from Amazon.com and made a bracket. I really like this look. No extra mess from tire spray after riding wet / muddy conditions.

Bark Busters / Hand Guards w/ removable shields - They were 50% off at Cycle Gear ($45). Too cheap to pass up. I like them and found that they actually deflect a TON of cold air, which was a happy improvement!

All new wheel bearings (front and rear)

Upgraded Steering bearing kit



Tank comparison:





New tank over the stock rubber mount:





Rear tank mount above and behind the stock tank mount:





XT225 horn relocation bracket (note the new hole I drilled to move the tank forward a little bit), on top of a rubber grommet, and bolted to the factory mount point on the frame (see post #20 below for pic of the rear OEM tank mount, which is just bolted on top of the aluminum bracket). I may actually convert this to non-rubber mount with steel bracket if the rubber/aluminum is too weak / flexible.





Modified front tank pucks:





Before:





After:





Another view:





Another view, with my boy begging to go for a spin






...
 

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Discussion Starter #2
Continued...



Front marker lights / turn signals OFF:





Front marker lights ON:





Replacing the Air Filter Element:





Checking the Valves and Cam Chain Adjuster:





Tail Light / Plate Mod:





With tail light OFF:





With tail light ON:







That's pretty much it for now... If we can just get some warmer / drier weather here in Oregon to melt the mountain snow, the adventures can begin!!!!!!!!!!!!!
 

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Initial Test Ride with some buddies a few nights after completion: (pics taken around midnight in dark conditions, with long exposure) ... And yeah, it was a work night!












 

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Your bike is looking great! Is that the Edge 2 taillight? How was installing the steering bearings? Thats the next thing I should do with my bike.
 

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Wow, you've been a busy feller! Your bike will be good to go for quite awhile now. I too have been thinking of that extra gallon. Cute boy, and good job with the mods!
 

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Looks great! And 4 gallons is like a dream come true.



I noticed the dual rear sprockets. How is that working out for you? Do you change the ratio often? I have the same thing and I find I leave it on the larger sprocket most of the time.
 

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Your bike is looking great! Is that the Edge 2 taillight? How was installing the steering bearings? Thats the next thing I should do with my bike.


Thanks! The tail light is actually just a generic one from amazon. It was like $22, and plugged right in to the stock wires.

The steering bearings were so easy... I was worried they would be challenging but they weren't. Easy with basic tools, no press required. When I pulled it apart, the little ball bearings went everywhere! I was so happy to be replacing them with true conical bearings. I set mine (the bearing pre-load) a tiny bit tight and within 10 miles it was perfect. The rear bearings took extra work to get out without the special expanding bearing removal tool (since the axle housing is so wide)... but my cousin had them out in a few minutes.
 

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Wow, you've been a busy feller! Your bike will be good to go for quite awhile now. I too have been thinking of that extra gallon. Cute boy, and good job with the mods!


Thank you for that.
It's definitely good piece of mind to do some of this stuff. I've had the T-dub a couple years and figured I should do some of this maintanance. The steering bearings were shot, but the axle bearings were in pretty good shape. It was only like $65 total for all the bearings and most of that was the steering upgrade bearing kit.
 

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Discussion Starter #10
Looks great! And 4 gallons is like a dream come true.



I noticed the dual rear sprockets. How is that working out for you? Do you change the ratio often? I have the same thing and I find I leave it on the larger sprocket most of the time.


Thanks! It's funny, I too usually leave it on the 50 tooth sprocket as it serves all purposes so well (pavement, gravel, trails, wheelies, etc). There have been a few rides that I should have popped it over to the 47 tooth as it makes 55mph so much nicer. But it got me into trouble once on a more extreme / technical trail ride, so I am hesitant to run it as our trips sometimes go from easy to crazy...
 

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Thanks for the great write up and pictures!

That is the tank I want to get for my bike and I just read the thread that Justgastanks is offering a discount to us.

Now I'm just going to have to buy one....
 

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Great write up on the tank install.Thinking I just might have to get me one.

How does the bike feel with the tank filled?

Looking forward to the pictures with the side panels trimmed and installed.



Your son looks like he is ready to go.It won't be long and you are going to need another TW.


I had my four year old granddaughter for a putt around the yard yesterday and she loved it.I can't wait until I can teach her to ride it.
 

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Great write up on the tank install.Thinking I just might have to get me one.

How does the bike feel with the tank filled?

Looking forward to the pictures with the side panels trimmed and installed.



Your son looks like he is ready to go.It won't be long and you are going to need another TW.


I had my four year old granddaughter for a putt around the yard yesterday and she loved it.I can't wait until I can teach her to ride it.


Thank you. I really haven't noticed the extra weight. I haven't done any technical trails yet, which is probably where you would notice it ... i.e. when you're having to lug the bike around on really off camber, rugged, steep terrain. But at most (with a full tank) you could be carrying about 16 extra pounds. Heck, if you worried about it, you could just put two gallons in for those type of trips and only fill it for longer adventures. Or maybe I'll use it as an excuse to lose 16lbs!
That's probably the best idea for me!

My son definitely loves riding around on the front. I'm super careful and don't go fast at all. Plus, in Oregon, we have some newer laws that say this activity is child endagerment, with heavy fines (sigh). So, I'd rather not risk it much. Unfortunately.
 

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As promised, here are the pics on modding the side plastic for the tank. Turned out easier than I expected. Just used a razor blade knife / box cutter type tool. Heated it with propane torch and could cut an inch or so at a time. Here's how it turned out...























 

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Thanks guys.


I forgot to mention that I removed the plastic pin behind the left side plastic the used to go into a tab on the original tank. I wanted to keep it on there just in case, but it had to go to work... So off it came.
 

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You know what works really well for trimming the plastics? Tin snips! I was an idiot and had a side bag on the exhaust side of my bike, and after a little while I smelled burning. The plastic was melted to my exhaust, it was ugly to say the least. I looks around the garage when I got back and saw my tin snips and trimmed off the melted section, like a hot life thru butter, even left a nice edge. Sometimes it's better to be lucky than good.
 

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You know what works really well for trimming the plastics? Tin snips! I was an idiot and had a side bag on the exhaust side of my bike, and after a little while I smelled burning. The plastic was melted to my exhaust, it was ugly to say the least. I looks around the garage when I got back and saw my tin snips and trimmed off the melted section, like a hot life thru butter, even left a nice edge. Sometimes it's better to be lucky than good.


Good to know Chip! Thanks for the advice.
 

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Update #2:



I Rode 150+ miles which included everything from 65mph on I-5 to wheelie's in alleyways, to urban trail riding, and even flying off of a wooden jump. The tank is doing great. And having a ~280 mile range takes the fuel stress away.




I have some more pics and info to share... Hope this helps all you folks who just ordered this tank on the sweet group-buy at justgastanks.com!



Here are some pics of the finished rear tank mount:















Tank from underneath: (looks really close but it's still about 1" away from the engine)







Front fender update:

I tried a 2004-ish YZ250 front fender (Cycra). It looked kinda nice from the front, but I did not like the side view. Kinda looks like a big beak or nose or something... It did however mount very easilly with my all-thread mounting setup.








Also had to trim 1" off the rear of the fender, because it hit the header pipe







So, I decided to go retro and try the stock fender with a 1970's era rubber flapper out front. Made from an old mud flap off my cousin's Chevy:







This setup suits me and my bike better.




 
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