XR400 large fuel tank

My dad mainly uses my Honda XR400 but he complains about the small tank on it.

So he gave me the go ahead on buying a larger one, and went with the Acerbis 5,8 gallon.

Since he paid for it I let him open the box once it arrived and the stupid Swedish taxes ~$100 extra on the price were paid:

Bad picture but at least he looks happy!

Stock vs Acerbis (this is the transparent one):

The instructions are quite good, needed to reuse the bolts and rubber spacers from the old tank:

If you do this do yourself a favor and order a set of new rubbers, the metal insert is easy to pry out but old hard rubber parts are a real hassle to work with, some WD-40 help but it was still a struggle and for a few bucks each its worth getting 2 new, partsnumber: 17508-KN5-670

One done one more to go …puuuh:

A little tricky mounting the petcocks, and take care since the screws just thread into the plastic, no inserts here:

Even with the supplied extra support in place there was a gap so we added some extra foam, cut from a knee pad insert, goes down along the frame a little on the left side to push the tank out a little since this has some extra wiring the gap on the left side was a little to small and the wires rubbed when turing the handlebars:

Bit of a gap here, but didn´t need that much force to bolt get it bolted up:

Once in place the indicators wont clear the tank so they need to be relocated:

The speedo cable guide on the right side needed to be bent up to not hit the tank:

The supplied fuel hose felt quite hard and stiff, have been spoiled since I bought some expensive Tygon fuel hose but its so easy to work with, slips right in place.

An angled fuel filter also helped getting more room to easier access the choke lever:

The rubber strap holding the back of the tank was all cracked, so we made a new one out of a strip of inner tube, a new can be bought for $10, partsnr: 17516-MN1-670

A quick relocation of the indicators, since moved at least one is broken (it was cracked already and have now failed) so need to sort that out in a better way, please no comments about my dads long underwear with skulls on them:

Pushing it to the pump, we had some fuel in the old tank but wanted to see how much it holds:

And we could squeeze 20 liters into it (~5,3 gallons) so its coming up half a gallon short of the 5,8 they sell it as but its still a big improvement:

It fired right up and my dad drove off into the sunset: