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I followed the helpful instructions in "synopsis of xt350 tank install" by Peruano who installed metal stock XT350 tank. I thought it might help to show it with the Clarke Tank and with using flat stock for the rear bracket (Peruano used steel from a printer bracket). I also modified the stock TW200 seat by shortening the tongue and moving the suction cup.

TW200 1.8 gals to Clarke XT350 4.0 gals. Read Photo Captions for some detail on procedure.



Before

After

Tank Comparisons TW200 1.8 gals vs Clarke XT350 4.0 gals

Tank comparing the thicker rear attachment point

 

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The Bracket using Peruano's instruction but with flat stock steel. Used stock bolt that held down seat for the under side of bracket that hold the stub that was cut off. Used M6 1cm bolt to fasten bracket to frame and M6 2cm bolt with washer for tank hold down to bracket (in other photo with tank installed)

Bracket under view

Bracket parts (minus the bolt to frame)

 

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Building up Tank recess for rubber doughnut (moves tank backward to allow more handlebar turning range

Rubber attached to tank with contact cement.

Tank on bracket

Tank bolted down to new bracket

Follow Peruano's instruction on cutting ridges and edge in seat plastic underside for flex fit, Here is where I cut the two ridges and sliced outer edge.

Seat on BEFORE cutting down the tongue

After Cutting the Seat Tongue, Much Better Fit

Wrinkles in Seat hidden by ATV seat cover

 

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Seat Plastic and foam to be cut exposed and marked

Drill a new hole for rubber suction cup (5/8" chisel drill bit) slide in this plywood and bolt to keep from drilling into foam or vinyl.

New suction cup location

Trim down plastic ridges at new lip for flush fit against tank

Moddified Seat Underside

Modified Seat - With Shorter tongue and relocated rubber suction cup.

No grommet on Clarke tank for side plastic to attach. I used a cable tie. drilled small hole in plastic tab base wrapped cable tie around frame.

 

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Clarke Tank comes with a steel rod that secures tank by being routed below frame tube.

Tank Rod installed

Final fit with shortened tongue

Now let's go ride...longer, farther.

ALSO - THE STOCK TW200 FUEL PETCOCK VALVE WORKS but use the rubber gasket that comes with the tank along with the stock set-up. Mine had a slight leak so I also use Honda Elastic Gasket in a tube - it resists gasoline and makes a nice seal.



Hope this helps those wanting to add the Clarke XT350 Tank on their Tdub.

 

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Thanks guys. I'm happy with it. Thanks to the "synopsis of XT350 install" post and the many other helps I've received from this forum.