Bigger gas tank for 2003 450EXC

[James Adams]

I'm having difficulty finding any large fuel tank options for my '03 450 EXC except for the $afari tank, which also requires a seat change. Are there any other options that fit with minor modifications?

[tHEtREV]

I though the 03 would accept the 04 to 07 tanks with no midification.

I know you need an 03 seat to fit a 03 to 07 tank on a pre 03 EXC.

I'm running a tank was fitted to an 06 EXC on my 00 200, all I had to do was fit the 03 seat.

Edit, I just did a part number search for the 03 450 exc tank (5900701350044) and it shows the following models use the same part...
(remembering that this list only includes bikes with this part number and wont include thos that use a different part number because the tank is a different colour).

KTM	450 EXC	2005
KTM	250 EXC RACING	2006
KTM	250 EXC RACING	2005
KTM	525 EXC	2004
KTM	250 EXC RACING	2004
KTM	450 EXC	2003
KTM	250 EXC RACING	2003
KTM	525 EXC	2005
KTM	525 EXC	2003
KTM	525 EXC	2006
KTM	450 EXC	2006
KTM	450 EXC	2004

[Off the grid]

I'm pretty sure there are differences between 02-07. My 05 Clarke tank did not fit on my buddies 02 450.

To answer your question, Clarke makes a good tank, but were I to do it again I would get the KTM hardparts tank, it's the same size (3.1gallons) but looks fkn cool. They extend your range to about 120-140miles per tank depending on your right hand.

*Edit as far as larger tanks I think the supply is limited. There are 1gal auxiliary tanks you can buy though.

[James Adams]

After consulting with a few other folks, I have a 6.6-gallon Acerbis on the way. It sounds as though it will fit well enough for my use.

[tHEtREV]

Originally Posted by Off the grid

I'm pretty sure there are differences between 02-07. My 05 Clarke tank did not fit on my buddies 02 450.

Any idea what the problem was?

I know the seat doesn't fit the tank unless you trim the front of it, but I thought that was all.

[Off the grid]

Originally Posted by tHEtREV

Any idea what the problem was?

I know the seat doesn't fit the tank unless you trim the front of it, but I thought that was all.

I don't remember unfortunately. Might be the location of the tank mounting stem.

[cedric]

The dual headers and the kickstarter are different and that may be the issue. I had to change my kicker to get an '03 stock tank to fit my '02.

[James Adams]

Originally Posted by cedric

The dual headers and the kickstarter are different and that may be the issue. I had to change my kicker to get an '03 stock tank to fit my '02.

There's a small tab on the dual headers that interferes with the support brace for the 6.6-gal Acerbis tank. I think I can clearance it with a hammer and vise but I have other work to do on the bike first. It does look like some minor seat modification will also be required.

[pcvance]

Originally Posted by James Adams

I'm having difficulty finding any large fuel tank options for my '03 450 EXC except for the $afari tank, which also requires a seat change. Are there any other options that fit with minor modifications?

Here's my 04' EXC fitted with an 05' XC 3.6 gallon tank and seat, no fit up issues. The stock EXC seat will fit but with gap issues along the tank and airbox. I also added a Baja designs 1.1 rear tank for a total of 4.7 gallons. The bike will now go 200+ miles, plenty of range. The 6.6 Acerbis seems like overkill. FYI, the tank and seat cost me $150.00 on CL, they were both like new. The only problem is my KTM hard parts radiator guards don't fit, but the tank itself offers decent protection for the radiators.

[James Adams]

Originally Posted by James Adams

There's a small tab on the dual headers that interferes with the support brace for the 6.6-gal Acerbis tank. I think I can clearance it with a hammer and vise but I have other work to do on the bike first. It does look like some minor seat modification will also be required.

Just a quick update. I've ordered an aftermarket header for my '03 450EXC that should allow me to install the lower tank braces on the big Acerbis tank. We'll see...

[rattlinjack]

Originally Posted by James Adams

Just a quick update. I've ordered an aftermarket header for my '03 450EXC that should allow me to install the lower tank braces on the big Acerbis tank. We'll see...

Gday James!
Very interested in the outcome here..
I'm going through the same search, here in Australia, Bigger tank needed, no luck so far..

So, what sort of after market header have you ordered? "Mines damaged" so I need a new one

[James Adams]

Originally Posted by rattlinjack

Gday James!
Very interested in the outcome here..
I'm going through the same search, here in Australia, Bigger tank needed, no luck so far..

So, what sort of after market header have you ordered? "Mines damaged" so I need a new one

It's an FMF titanium PowerBomb header, it turned up on eBay and the price was very right.

[rattlinjack]

Originally Posted by James Adams

It's an FMF titanium PowerBomb header, it turned up on eBay and the price was very right.

Good stuff! Is it a 2003 one? or do later models fit?

[Ellusivebull]

I have an 03 300 exc and would also like to know how it turns out. I have been trying to figure out if I can order the 6.6 and make it work. What was the seat issue that you had and how did you overcome it? Any pictures of a finished product? Thanks

Joey

[tHEtREV]

I was playing around with my 6.6 when I got it and put it on my 00 200exc for a test fit.

I had an 03 seat on it and was using a later model tank.

The tank fit OK, but the tank braces that come with the kit wouldn't work, you would have to make new ones, and the seat mounting tabs wouldn't line up with the mounting nuts, they were a centimeter or two to far back.

I didn't try to fit it properly, it was just a test fit and I have since sold the 200.

There was a guy on this thread that fitted one to his 250sx so it must be possible.