The XR250, XR400, XR600 and XR650L Acerbis tanks are all identical and can be made to work. However, I found that the XR650L tanks come with extra brackets that make this job easier than the others.
The first 650L bracket is the upper engine mount bracket, this bolts right up to the DR upper engine mount like it was made for it. What I did was take two M8 nuts with 13mm hexes and press one into each end of the bracket. I just layed the nut on the ground and tapped the bracket on top with a hammer. Here is what it looks like mounted up...
Next I used two pieces of aluminum flat stock to go from the tank to the engine mount bracket.
For the rear mount, I again used the included 650L bracket. This will tie into the origional DR tank braket. You can cut the DR bracket and tie it together with a pice of aluminum. I wanted to keep the stock bracket intact so I could swap back to the stock tank if I need to. To do this, I had to grind the two ears of the DR bracket down so they would clear the tank. Then I tied the stock DR bracket to the 650L bracket with a piece of aluminum.
Now when installing the tank, I did not need to cut the rubber bumper studs off of the frame. I left the rubber plugs on and sprayed them with some WD-40. You'll just need to spread the tank with both hands a bit when pushing it down over the pucks. It's a bit stiff at first but once it's on the tank will reshape it self a little so the next time you take it on and off it will go easy. To make this easier, you could heat the under side of the tank with a heat gun a bit making it easier to spread apart a little.
If fits like it was made for the bike, it seems like the front of the seat meets with the tank better than the DR speciffic Acerbis tank.
With this tank, I have a 350 mile range.
Last edited by Jeff@TheQuadShop; 12 Jan 2016 at 04:51.
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