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#1
07-05-2008, 06:21 PM
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Dumb 07 gas tank design.
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.
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04 Montesa 315R, 07 EC300, 21 KTM Erzberg 300, 21 Sherco 300 SEF-F, 23 KTM 690, 23 Rieju Mr Pro 300 
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#2
07-05-2008, 07:12 PM
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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.
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2002 Gasgas EC250 (gone not forgotten) 2012 Ktm 300xc 2001 Gasgas EC300 Lifes journey is not to arrive safely at the grave in a well preserved body, But rather to skid in sideways totally worn out shouting holy cow what a ride !!!!
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#3
07-06-2008, 07:27 AM
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Quote:
__________________
04 Montesa 315R, 07 EC300, 21 KTM Erzberg 300, 21 Sherco 300 SEF-F, 23 KTM 690, 23 Rieju Mr Pro 300
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#4
07-06-2008, 12:44 PM
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They have been doing it from 1998 as far as i know, mabe even later.
__________________
2002 Gasgas EC250 (gone not forgotten) 2012 Ktm 300xc 2001 Gasgas EC300 Lifes journey is not to arrive safely at the grave in a well preserved body, But rather to skid in sideways totally worn out shouting holy cow what a ride !!!!
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#5
07-06-2008, 01:46 PM
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Quote:
When I had my 2001 GG, I filled in the area with a plastic welder. Held up really well.
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#6
07-06-2008, 02:49 PM
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Quote:
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? 
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04 Montesa 315R, 07 EC300, 21 KTM Erzberg 300, 21 Sherco 300 SEF-F, 23 KTM 690, 23 Rieju Mr Pro 300
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