Honda XR650L Larger Gas Tank | Upgrade Options That Work

Riders seeking a Honda XR650L larger gas tank are usually looking to cut fuel stops on long backcountry runs or multi-day trips. Three well-established aftermarket brands offer bolt-on replacements that double or nearly double that range, each with different trade-offs in capacity, bodywork fit, and install steps. Here is what fits, what to watch for, and how the swap works.

Why Upgrade the XR650L Fuel Tank?

The XR650L is a 644cc air-cooled single that Honda has kept in near-constant production since 1993. Its stock tank is adequate for commuting and short trail loops, but the dual-sport crowd routinely pushes 100+ mile days where a gas station isn’t around the next corner. A larger tank adds 1.2 to 3.0 gallons over stock without requiring permanent bike modifications — the swap is reversible and uses existing mounting points. The trade-off is added weight up high (especially when full) and, with some tanks, the loss of stock radiator shrouds or a slightly wider stance.

Best Larger Gas Tank Options for the XR650L

Three brands dominate the XR650L aftermarket fuel tank scene: Acerbis, IMS, and Clarke. Each fits the 1993–2024 model years in slightly different ways, and none require cutting or welding. The table below lays out the key specs and compatibility details.

For a closer look at how these tanks compare in real-world use — including fit quirks, install difficulty, and rider feedback — our tested roundup of the best XR650L fuel tank upgrades covers each option with practical notes. The Acerbis 5.8 is the range king but sits wide; the IMS 4.0 is the easiest to live with day-to-day; the Clarke 4.7 hits a middle ground if you can work without the stock bodywork.

How to Install a Larger Tank on the XR650L

The basic procedure is the same across all three aftermarket tanks, but three gotchas matter more than the order of bolts. First, clean the new tank thoroughly before mounting it — molding and drilling leaves plastic shavings inside that will clog your petcock and carburetor if you skip this step. Flush it with fuel or compressed air and inspect with a flashlight. Second, confirm petcock compatibility: the IMS 4.0 requires the stock OEM petcock, while the Clarke 4.7 also uses the stock unit. The Acerbis 5.8 ships with its own petcock hardware. Never assume the tank includes one. Third, check bodywork fit — the Clarke 4.7 cannot use the stock radiator shrouds, so plan for that look or order aftermarket side panels before you start.

The installation sequence: remove the seat and side panels, disconnect the fuel line and drain the stock tank, unbolt and lift off the stock tank. Apply the foam strips supplied with the new tank (they prevent abrasion against the frame), install the petcock into the new tank, and set the tank in position. Secure it with the supplied mounting wire or bolt through the existing frame tab. Reconnect the fuel line — adding an inline fuel filter is cheap insurance — and route a vent hose with a check-valve vent line per the tank’s instructions. Reinstall the seat and side panels (or aftermarket replacements if the stock shrouds no longer fit). Check for leaks before starting the engine.