Hi,
I am attempting to move the coolant overflow tank from the front to under the seat, behind the battery box.  How did you do it?  I have removed the battery box and think that if I put the tank against the rear inner fender, it will not clear the b. box upon reinstall.  Did you remove the rear inner fender and somehow place the tank between the cross bar and fender?  If so, how did you clear the seat pan and what did you do with the CDI?  Sheesh, I cannot remember what the install looked like.
If you can, please help.
Regards,
John Mc

John while I have not done this mod; many people have used an overflow tank from 250 ninja's.  I miss the info we lost, but iirc very few  keep the old reservoir when doing this mod

I tried ordering one from fleabay and what I got was so brittle that when I began to wash it, it broke apart.  I think I may have figured this out.  I will probably loose the tool tray, but it appears there is enough room to velcro the thing onto the inner rear fender and get the battery box back in.  If that works, I can possibly modify the tool tray (read butcher it so that it will still retain the battery) and have use of the front part of the tray.
This is one of many projects going on with the bike.
Regards,
John Mc

I went the route of getting an overflow bottle from an EX250 from FleaBay as Snarf mentioned.  I lucked out and got one in good condition for around $7 I think.  I mounted it under the right side cover using metal plumbing strapping.  I think lots of folks do just relocate the stock overflow tank to under the seat just behind the  battery box.  My guess is that they secure it in place with something similar to what I used.  As far as I remember, it should fit in there without any problems.  I carry my portable compressor in this spot.  I'm not sure about the tool tray clearance though.  My bike was missing it when I got it so I have no idea how it fits under there and how much room one takes up.  I carry my tool pouch and the locking cable that I never use in the little area behind the seat latch mechanism.

Marlan

Pardon me for being curious, but this is one mod I never have understood. The coolant overflow tank does not have hot coolant running through it all the time as it is not a part of the dedicated cooling system. Therefore
coolant only transfers to the bottle when excess pressure builds up. Once in the tank the coolant cools off and
therefore does not contribute to engine heat. Stop me if I'm missing something here. Increasing air flow under the engine is the only reason I can see for doing this.   

I think the reasoning behind this is twofold. 1. It lets more cooling air under the engine, and 2. It makes it easier to check coolant level and fill as necessary.

Jim

My reasoning behind moving the overflow bottle was pretty much just for ease of access.  I have the side covers off frequently enough that I'll see the bottle and notice if it's low.  I'm not sure if relocating the bottle has any affect on engine cooling or not.....doubt it.  I figure any increase in airflow at the bottom of the engine is going to have a minimal impact but then again, it can't hurt.

OK, I got it moved.  It does fit pretty nicely behind the battery.  Why do it?  Easier to check (at the age where squatting down or bending over very far aren't as easy as they once were) and there has to be some help in cooling things around the headers.  It is hot and humid in Southeast Louisiana, and anything to reduce heat on the rider is worth trying.  I have heat shields and I am now considering more holes in the belly pan.

 
Check back issues of Concourier and Man of Blues (MOB) had pictures and step by step instructions on this very same procedure using the stock coolent tank and hoses.

HTH,

Check back issues of Concourier and Man of Blues (MOB) had pictures and step by step instructions on this very same procedure using the stock coolent tank and hoses.

HTH,

yes, I think his finger slipped when he typed MPB...(MOB)..

I did the mod originally because of the need to hide the jug, it first appeared on the Nekid COGZilla bike, and I didn't want that thing sitting out there like a sore thumb.

Fixed it for ya....

I will be relocating jug also due to going naked and no I don't have to just want to. Thanks to the op. Now I don't have to ask how.
Toon