Dumb 07 gas tank design.

[Ud_luz]

I clipped a small vine today with my 07 300. Where the top shroud screw attaches to the tank failed. It actually pulled out a plug of plastic about 1/4" in diameter and 1/4" long. It broke at the bottom of the plug. Looking at this setup it appears they molded this on purpose this way. Since it's slightly tapered I can't glue the plug back in since it's larger at the bottom then the top. It's the weirdest plastic molding I've ever seen. I don't even understand how they could have possibly done this unless it is a separate piece that is installed before they attach the top black part of the tank to the bottom natural colored part.

Since I can't put the plug back in does anybody have an idea of what I could fill the hole with so I may screw in the top shroud screw? I've heard of plastic welding. Is this feasible? As easily as it broke I'm surprised I haven't heard of this problem yet.

Thanks, Bill.

 

[2 strokes 4 life]

I have done the same thing. I used JB wled to fill the hole with. Seems to be working, but i ordered a clarke tank just in case.

 

[Ud_luz]

I have done the same thing. I used JB wled to fill the hole with. Seems to be working, but i ordered a clarke tank just in case.

They did this on other years too? I wonder what the reason is?

 

[2 strokes 4 life]

They have been doing it from 1998 as far as i know, mabe even later.

 

[gasgasman]

It actually pulled out a plug of plastic about 1/4" in diameter and 1/4" long.

Would you rather the tank get damaged and leak?

When I had my 2001 GG, I filled in the area with a plastic welder.
Held up really well.

 

[Ud_luz]

Would you rather the tank get damaged and leak?

When I had my 2001 GG, I filled in the area with a plastic welder.
Held up really well.

KTM tanks don't break, everything else might in a crash but not the tanks. Lots of personal experience in this regard.

I love hardware stores. I picked up one of these Wood Insert and set it in the hole with plastic weld epoxy. I used the 10-32 size which almost pushed into the hole without threading it in. I used the unflanged unit and shortened it slightly with a grinder.

I think it will still pull out before damaging anything and it will be very easy to fix.

Did I happen to mention, I love hardware stores?