DAMN Riders - No rules, Just ride!

The big gas tank (Clarke 3.9 or whatever) on my DRZ400 leaks around/through the threads for the completely unnecessary crossbar at the front. At the Shenandoah 500, I plugged this hole with gas tank repair goop and it worked fine for that trip and for a month afterward, but now it leaks again because said goop can't really get a good purchase on the plastic and because it gets hard and separates from the tank. What is the best way to permanently fix this weep (aka less than a "leak" but more than a "seep")? I'm willing to do whatever, since I actually have a brand new replacement but honestly since this is the first replacement (which replaced a tank with exactly the same condition), I'd rather try to fix this one permanently and leave the other one in the box, since the other one in the box could very possibly have the same problem. And this way I get a free spare for my troubles. ;)

Anyway, I'm not putting the crossbar back in and the leak is behind the front fairing wing-things and hidden from view, so I'm willing to do what it takes to fix it.


Thanks,

~Patrick

Direct the drip to the exhaust area, problem solved
Big Bird seems to be good at cutting plastic tanks into pieces and screwing them back together again...perhaps he will lend his advise.

Boom Boom wrote:Direct the drip to the exhaust area, problem solved
Big Bird seems to be good at cutting plastic tanks into pieces and screwing them back together again...perhaps he will lend his advise.

oh THAT was COLD!

Use a soldering iron to melt the hole shut. If you have to add material, use the grey electrical conduit PVC.

JB Weld is awesome.

juddspaintballs wrote:Use a soldering iron to melt the hole shut. If you have to add material, use the grey electrical conduit PVC.

This. Or get/borrow a plastic wielder. I think either BigBird or Kyler have one.

Wingfixer wrote:

juddspaintballs wrote:Use a soldering iron to melt the hole shut. If you have to add material, use the grey electrical conduit PVC.

This. Or get/borrow a plastic wielder. I think either BigBird or Kyler have one.

must be Sam - all I have is MIG.

BillyGoat wrote:JB Weld is awesome.

I second this ,I did a repair with the JB weld on a KLX250R and that was........10 years ago . The bike was sold but I never heard that the tank ever leaked from the friend that bought it . Clean it really good and scratch/scuff up the area,I actually used like 60 grit cloth around the repair.

Thanks for the help, all. I'll take these into consideration and make that call I owe to Sam and let you guys know if it works.


Thanks,

~Patrick