-->> 96-01 YZ250 tank conversion to 02-08 tank conversion made simple <<--

[phantomette]

YZ 02 FUEL TANK MOUNT

I decided to do this mod before I even joined ATM but now that I got some helpful modd tips and pointers from here, I am psting my project to you guys now with really descriptive pictures to help you guys understand better how simple this mod really is!! I own a 1999 YZ250 and switched from a 99 tank to an 02 tank. I love the look of the 02-08 bikes and now mine looks like one!!

You'll know materials used and tools used to get the job done!

First off, start by going to LOWES (PREFERRABLE where I went) or HOME DEPOT

Materials you will buy:

2 hex bolts... 6mm (M6)-1.00 x 40 (these bolt the brackets to the fuel tank)

1 pack of 4... 6mm (M6)-1.00 x 10 (these bolt the tank to the frame, you will only need 2 of these)

2 packages of washers...hole sizes 1/4"
(large washer is 7/8" wide and small washer is 5/8" wide)

1 Package of 6mm (M6) Hex nuts class 8

1 Package of 1/4" lock split washers

Aluminum flat rod 1/8" thick x 3/4" wide x 3' ft long
(you will be using this to cut your bracket pieces)
**you can find this in the isle w/ the aluminum L metal and dowel rods, it will come in a 3 ft or so long strip.

HERE'S A LOOK AT THE SIZES OF WHAT YOULL NEED




OKAY NOW FOR THE BRACKET FABS: The piece of aluminum bracket material you buy from lowes will look like this in thickness and width, but it will be a 3-4 ft long piece, so you will only b cutting the custom length of what is told of 2" I found it best to cut the four brackets to 2" in length, here is a just cut and shaped bracket using a 4 1/2" angle grinder: total finish lengh should be:
1/8" x 3/4" x 2" (cut 4 of these) and round the corners slighly or not up to you


This is the tool I use:


NOW DRILL HOLES:I now used a 9/32 drill bit....I made my holes 1 1/4" on center from each other, this allowed for better play for the seat to match up with the back seat mount holes. So you can go 1 1/4" to 1 1/8" on center this will be fine, and give enough clearence to tighten the bolts later that will attach the tank to the frame w/ a ratchet and socket.
**note: I find that drilling one hole first and then measure for your other hole on center works best. in the end the brackets should look like this:


NOW THAT THE HARD PART IS OVER

Now your gonna mount your screws and washers (hardware) to the 02 tank mounts and tighten them a little at this point you want to test fit the tank and know how your brackets will align to the frames holes! I RECOMMEND DOING THIS PART WITH THE SEAT ON AND MAKING SURE THE SEAT ALIGNS WITH ITS BACK MOUNT HOLES AND THAT THE TANK LINES UP WITH ITS FRAME HOLES JUST MOVE THE BRACKETS UNTIL THEY ARE IN POSITION AND THE SEAT IS IN POSITION, IF YOU HAVE TO ADJUST THE RUBBER STOP UNDER THE TANK THATS ON THE FRAMES DO SO....once you got everything lined up take off the tank and tighten the brackets really good so they dont move hardly!

(here you will use these screws and washers for each side mount):
1 - 6mm - 1.00 x 40 hex bolt
1 - 7/8 washer
1 - 5/8 washer
1 lock waher
1 6mm hex nut

I made the line up easy of the order of the screws for each side:
(the white tank is not the tank I use just an example of how the screws go up close!!)

(THESE ARE NOT TIGHTENED OF COURSE LOL)




02 tank w/ brackets


ALMOST DONE.....NOW TO MOUNT THE TANK
It should look like this when you mount the tank onto the frame....this shows where the tank should sit and as well where that rubber stop under the tank should sit to make the tank sit nice w the frame holes and as well have the seat fit perfect w/ its mount holes as well!

(RUBBER TANK STOP POSITION)


(LEFT SIDE BRACKET)

(RIGHT SIDE BRACKET)


THE FINAL TANK RESULTS!
with my instructions and time spent less than $10-15 and 1 hour of work or less is all it takes to mount this sweet tank to your 96-01 YZ125 or 250.

(THIS IS THE FINAL LOOK OF THE TANK MOUNTED AND THE SEAT LOOKS NICE AND FLUSH!)



HOPE THIS HELPS YOU ON YOUR MODDING OF YOUR TANKS NOW, I TRIED TO MAKE IT SIMPLE AND TO THE POINT. IF YOU GUYS HAVE THOUGHTS ON WETHER AN 02 SEAT AS WELL AS AN 02-08 AIR FILTER BOX WOULD MOUNT UP INFO OR POINTERS WOULD GLADLY BE APPRECIATED, AS WELL IF SOMEONE WANTS TO DONATE A SEAT AND FILTER BOX I CAN SEE IF THIS WOULD WORK.

Part 2 will be 02 Tank shroud fab! ......(COMING SOON) WAITING ON SHROUDS TO COME IN, IN A FEW DAYS)

[phantomette]

RESERVED FOR SHROUD CONVERSION! (COMING SOON!)

[Woody_393]

GREAT work, and thank you for sharing. It's posts like this that really make ATM, what it is today.

Thank you! This is Knowledge Base material once you are done!

[phantomette]

thanks I just like things to be discriptive and very visual, glad this can help!

[ClosedCasket]

Awesome ! I happen to be a big fan of conversions Nice work man