Wife's KDX200 tank started leaking around petcock. Replaced the gasket. Don't know if it was cracked prior, but after replacing the gasket I noticed the crack - I may have just overtightened the bolt and cracked the tank...don't know.
Ordered IMS tank, but the shrouds they sent didn't fit right - wouldn't mount up as if they were designed too narrow for the width of the radiator.
IMS wants me to send it back for exchange, but now I'm thinking why not attempt to repair it so she can ride in the mean time?
I've seen JB weld used, but that was on a puncture. The other thing that concerns me is that this crack bisects where the petcock gasket is, going from one of the bolt mounts away from the petcock.
Will JB weld do it? Will I be able to make it smooth enough for the gasket to work?
Any other suggestions?

Although Ive seen it used on a variety of materials, they dont recommend it for plastic.
Maybe another plastic specific epoxy would be best.

http://jbweld.net/faq.php

sorry but it cant be done:cry: trust me ive tried it all on a kx80 tank with a crack in the same spot. it will hold for a while but it will leak again. buy a new tank or look on ebay.

I had the same problem with my IMS tank, the shrouds dont quite fit right. Good luck on the repair but I have never found anything that really works on plastic, I suggest going with a new tank.

I can't vouch for this but I read on another board that a guy has used glue meant for RC car fuel tanks...I guess it's very runny,almost like water but works well when dried...try your local RC car/airplane shop.It's worth a try,good luck.

Ah, try a product called "Seal -All" and you can get it at Home Depot. My first expereince with this was to fix a tank leak on a 1975 Ford F100 truck. The tank had a hole worn into it from the tank strap. Was told about this stuff by an old hot rodder. Well, while the hole was dripping gas, took a dab on the thumb, set it on the leak, held it for a minute. Leak was stopped, added some more, let dry and it never leaked again, ever. Now keep in mind, it was sealed while it was leaking gas.

I'm don't have any faith in a glue repair of polyethelyne plastic but if you try it keep in mind that you had premix in that tank and clean it GOOD.

If you can get to it, ive used a plastic welder, its basicly a sodering gun that you run beeds of plastic through and it will seal the leak 100%!

toyota_mdt_tech said:

i have also used this product with great success on a 1984 XR500R tank that had a crack. I got mine from Auto Zone.

hey i used jb weld(or off brand at wal mart) on my tw200 tank and it works great!! hasnt leaked in about a month(when i put it on the tank!) so for those of you so say it dont work

pkley said:

I bought a plastic welder from Harbor Freight Salvage on sale for about 20 bucks. Its a heat gun with a small nozzel and has a air regulator on it and hooks to a compressor. It blows out very hot air in a small local area. I tried all the rod types that came with the gun and none of them worked either the rod melted first or the part melted first. I found out that the tank is made out of HDPE (high density polyethylene) I went on e-bay and found (Plastic welding Rod) 5 Lbs is the smallest amount I could buy which is enough to do 500 tanks but it was only 15 dollars. I then found some old broken fenders and side covers at the local park and practiced. It seems to work real well. I havent yet done the tank but Im sure it will work. Its also around the Pet Cock. They form a cavity in the plastic then they install the nuts that the petcock bolts to, and then they bond a plate over the nuts. Its this glue bond that cracks because all the weight and vibration of the petcock is on the glue joint. Yours is probably the same. I tried everything JBweld, gas tank repair epoxy, and yet the best so far was a very hot soldering iron. But I have faith in the plastic welder. It puts down a real good bead on the parts I have tried so far and it becomes part of the part not just stuck on it like an adhesive. good luck. PS, they sell different colors to match the different bikes

skoot22 said:

Skoot, thats the stuff! I have some on hand right now and dont even have anything that leaks! I was sold after seeing it seal a dripping gas leak in a minute, while it was dripping gas!