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I can't believe this. But I can't get the gas tank off of the 2005 KDX 200 (POS) that I just bought. The tank has a 10 mm screw on each side of the tank that goes through the perimeter frame for solid mounting. But when I turn the 8 mm screws counterclockwise they just won't come out. Each one has some initial resistance then suddenly turns easily for maybe 1/4 turn. Again and again. I can keep that up until Jesus comes, but nothing happens ... tank still secure to the frame.

HELP!

Sounds like they are stripped.

Same thing, one side on my tank. Come winter I'm going to cut the head off the fasteners, remove the metal washers and rubber grommets, then cut down the fasteners just enough to get the tank out, but leaving enough to grab with vise-grips. Next some careful work with an old soldering iron to remelt the plastic around the threaded inserts so they will take some torque. Then some magic liquid un-seizer, some prayers...

I got mine out with an air wrench. Always use generous antiseize afterwards and haven't had any further problem.

Thanks for the helpful replies. Fortunately I was able to put the new petcock in without having to remove the tank so all is Ok for now. But one of these days I'm going to have to deal with it.

Hope one of the threaded inserts didn't let loose. If so, I cant think of any other option than to really mess up the tank to get it off. Best of luck!

When you do need the tank off try to slide something like a pocket screwdriver (or razor blade) behind the bolt head and pry (or pull) outwards while you're loosening the bolt. Most times it'll catch on a thread and come right out.