Tech: Installing an IMS Desert Tank on Project Honda 400EX - Extending the Range - ATV at Off-Road.com
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Tech: Installing an IMS Desert Tank on Project Honda 400EXExtending the Range
Publish date: Jan 1, 2003
By:  Justin Waters, Dean Waters
Source: ATV at Off-Road.com

A stock 400EX has a good range on a tank of fuel - around 60 miles. But we needed to extend it out a little farther so we could avoid an extra fuel stop during Hare Scrambles, and let us enjoy some LONG rides without worrying about fuel. We'll also be bumping-up the cc's in Project 400EX, and that means more fuel will be needed. Follow along with the installation of an IMS 4.3 gallon desert tank.

Installation

Stock fuel tank on Project 400EX, with plastic on
Naked 400EX with front plastic removed
The first thing you have to do is strip back the plastic so that you can get access to the stock fuel tank. After all the plastic is gone, remove the straps on each side and the two bolts holding the stock tank to to the frame.
Fuel valve on the stock tank
Screw that holds the seat
Next disconnect the fuel hose. Your stock tank will now be free. After you take the tank off and drain it (into an approved fuel container - NOT onto the ground!), you will need to remove the fuel valve on the bottom so it can be reused on the new IMS tank. Next take off the screw that holds the front of the seat down, and move it over to the IMS tank. Remove the bushings and place them on the new tank. Now attach the fuel valve to the bottom of the tank and you are ready to reinstall.
Move bushings from stock tank to new tank.
With hand guards I was unable to get full turn out of my handlebars. We ended up putting a longer Laeger steering stem.
Bolt down the IMS tank and reattach the fuel line. All plastic can now be reinstalled, with the exception of the original tank cover which is no longer used. With everything reinstalled we had to test our clearance. We are currently running Renthal 400EX bars with stock bend. We found that our Acerbis handguards hit our tank slightly at full lock. Everything cleared without the handguards. Since we wanted to keep our handguards we found we had a couple options:
1) We could limit our turning radius some and install a lock just before it hits. This would be adequate and it looked like we would still have a good turning radius.
2) We could install a longer steering stem. Since we were planning on adding an anti-vibration steering stem in the future anyway, we decided to go with this option and do it sooner rather than later. Watch for an installation article next month on our new Laeger anti-vibe steering stem.
A look at the new IMS tank from the side
New tank from the top
 
 

Summary We are now ready for some long-range trail rides, less fuel stops in our next race, and for that new 440 kit from Tudors Performance to consume some more fuel. The installation was straight forward, with the only catch being clearance around the tank depending on your handelbars and accessories. Looks? Some people like it, some people don't. We were after function, not looks, and it fits the bill perfectly. Parts List:

IMS Part #122227
MSRP $225
Colors: Natural, Red, and Black.
Options: Regular fill or Setup for Quick fill

  • Contact Information

IMS Products
6240 Box Springs Blvd. Unit E.
Riverside, CA 92507
Telephone: 909-653-7720 Fax: 909-653-1060
Toll Free: 800-237-9906
www.IMSProducts.com

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About the Author

Justin Waters

Contributing Author, Test Rider

A young gun from way back, Justin began racing ATVs and writing his impressions for Off-Road.com at 12 years old. Now an experienced hand with a wrench or a computer keyboard, he's a key contributor to several sections of Off-Road.com. His current 4x4 series includes Project "Off Road Toyota." Articles by Justin Waters

Dean Waters

Articles by Dean Waters
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Source: ATV at Off-Road.com, 1/1/2003
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