New gas tank from Clark MFG

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
Toonces
Member
Posts: 19
Joined: 04:19 pm Sep 21 2017
Country: USA

Re: New gas tank from Clark MFG

Post by Toonces »

Took my cracked tank to "Phil's Plastics" in Phoenix. The guy who does their plastic welding is brilliant. I told him I didn't care what the repair looked like but wanted it to be reliable above all. I'm pretty sure the tank will crack again later on. I'll be removing the tank while the bike is in storage shed during the hot months here (140 degrees in shed) in hopes that might help. In the mean time, I'll keep contacting Clarke. Hope you do too.
Attachments
KDX200g.jpg
KDX200g.jpg (386.07 KiB) Viewed 4315 times
koilyuf.jpg
koilyuf.jpg (229.43 KiB) Viewed 4315 times
gfrfd.jpg
gfrfd.jpg (201.32 KiB) Viewed 4315 times
User avatar
G22inSC
Supporting Member I
Supporting Member I
Posts: 513
Joined: 10:23 pm Jul 24 2006
Country: United States
Location: South Carolina

Re: New gas tank from Clark MFG

Post by G22inSC »

I would store full of fuel. Hopefully that will help it from cracking again while in storage.
'05 Kaw KDX200 ('00 KX125 forks / '02 RM125 Showa "K2" shock)
'14 Yam YZ125(x) (oldest boy's)
'22 Yam YZ125X (youngest boy's)
'17 Yam YZ85 (soon to be FOR SALE)
'10 Honda Recon (wife's)
'08 Kaw KX65 (Sold)
'07 KTM 50SX Sr. (Sold)
'09 Yam PW50 (retired)
'97 Kaw KX250 (Sold)

Gallery

2005 KDX200 Bike Profile
User avatar
doakley
Gold Member
Gold Member
Posts: 1241
Joined: 02:58 pm Mar 10 2016
Country:

Re: New gas tank from Clark MFG

Post by doakley »

I’d fill it with water. If it does crack you probably don’t want it dumping out fuel.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

You would store gasoline in a 140 degree shed? LOL Not for too long. HA HA :-)
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
G22inSC
Supporting Member I
Supporting Member I
Posts: 513
Joined: 10:23 pm Jul 24 2006
Country: United States
Location: South Carolina

Re: New gas tank from Clark MFG

Post by G22inSC »

KDXGarage wrote: 06:07 pm Jan 01 2021 You would store gasoline in a 140 degree shed? LOL Not for too long. HA HA :-)

Maybe I'm dumb but yes, I would. The fuel in the tank permeates through the plastic which would help with it not cracking. It's in a shed, away from the house and stored in a suitable container, ie the fuel tank. 140 degrees is no where near the auto ignition point of gasoline so the only issue I see is fuel vapors which would possibly exist at either 32 degrees or 140 degrees. Just be careful and don't walk around with a cigarette, etc.

If there's a chemist or Exxon employee here that disputes this please advise as I would love to hear what an expert says.
'05 Kaw KDX200 ('00 KX125 forks / '02 RM125 Showa "K2" shock)
'14 Yam YZ125(x) (oldest boy's)
'22 Yam YZ125X (youngest boy's)
'17 Yam YZ85 (soon to be FOR SALE)
'10 Honda Recon (wife's)
'08 Kaw KX65 (Sold)
'07 KTM 50SX Sr. (Sold)
'09 Yam PW50 (retired)
'97 Kaw KX250 (Sold)

Gallery

2005 KDX200 Bike Profile
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

I think the "good stuff" vapors will really fume off at 140. I don't think it will instantly ignite.

The manual says mix up a fresh batch each day. Storing it in a plastic jug (our fuel tanks) is not the best for it. I try to pull the hose off the carb and drain the fuel into a metal can, sealed. It may not be the best way, like a fresh daily mix, but it is better than leaving it in the tank.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

Toonces, those repairs look heavy duty!

What did that cost?
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
doakley
Gold Member
Gold Member
Posts: 1241
Joined: 02:58 pm Mar 10 2016
Country:

Re: New gas tank from Clark MFG

Post by doakley »

G22inSC wrote: 12:42 pm Jan 02 2021
KDXGarage wrote: 06:07 pm Jan 01 2021 You would store gasoline in a 140 degree shed? LOL Not for too long. HA HA :-)

Maybe I'm dumb but yes, I would. The fuel in the tank permeates through the plastic which would help with it not cracking. It's in a shed, away from the house and stored in a suitable container, ie the fuel tank. 140 degrees is no where near the auto ignition point of gasoline so the only issue I see is fuel vapors which would possibly exist at either 32 degrees or 140 degrees. Just be careful and don't walk around with a cigarette, etc.

If there's a chemist or Exxon employee here that disputes this please advise as I would love to hear what an expert says.
Actually, you are correct. The fuel in the tank permeates into the plastic but it also helps break down some of the long chain molecular bonds in the plastic. The common term is it causes the tank to "lose it's 'plasticizer'". Over time, generally a fair amount of time, this makes the plastic less pliable (or more brittle depending on your point of view) and more susceptible to cracks in areas of stress, around a screw fastener for example. It's not unlike "work hardening" in metals.
It's not that 140*F is going to cause the gas in your tank to ignite. It may, probably will, increase the rate of the degradation of the plastic tank which could help lead to a fuel leak. What happens as the heavier than air gas fumes spread about on the floor is open for question. Should those fumes happen to find an ignition source (spark from a light switch or electric tool?) what happens is decidedly not open for question. Roughly speaking a half cup of gasoline spilled out to vaporize in a confined area, has the explosive power of a couple of sticks of dynamite. Stored in a shed away from your home you are probably fine, especially if the shed has some floor level venting (or just isn't that tightly built). Certainly better off in a shed than left out in the sun which would only degrade the plastic faster.

Oh, and, yes, I am a chemist, FWIW.
User avatar
G22inSC
Supporting Member I
Supporting Member I
Posts: 513
Joined: 10:23 pm Jul 24 2006
Country: United States
Location: South Carolina

Re: New gas tank from Clark MFG

Post by G22inSC »

I agree, the vapor is the real issue and must prevent said vapors from finding a spark. That's the danger.
'05 Kaw KDX200 ('00 KX125 forks / '02 RM125 Showa "K2" shock)
'14 Yam YZ125(x) (oldest boy's)
'22 Yam YZ125X (youngest boy's)
'17 Yam YZ85 (soon to be FOR SALE)
'10 Honda Recon (wife's)
'08 Kaw KX65 (Sold)
'07 KTM 50SX Sr. (Sold)
'09 Yam PW50 (retired)
'97 Kaw KX250 (Sold)

Gallery

2005 KDX200 Bike Profile
User avatar
G22inSC
Supporting Member I
Supporting Member I
Posts: 513
Joined: 10:23 pm Jul 24 2006
Country: United States
Location: South Carolina

Re: New gas tank from Clark MFG

Post by G22inSC »

KDXGarage wrote: 02:02 pm Jan 02 2021 I think the "good stuff" vapors will really fume off at 140. I don't think it will instantly ignite.

The manual says mix up a fresh batch each day. Storing it in a plastic jug (our fuel tanks) is not the best for it. I try to pull the hose off the carb and drain the fuel into a metal can, sealed. It may not be the best way, like a fresh daily mix, but it is better than leaving it in the tank.

Very true. I try to mix just enough for the ride at hand and I don't store fuel in plastic tanks of any kind. In fact, I actually drain my tank after every ride just so the natural color doesn't become stained by the mix. Try to also drain the float bowl if it's going to be a while before the next ride.
'05 Kaw KDX200 ('00 KX125 forks / '02 RM125 Showa "K2" shock)
'14 Yam YZ125(x) (oldest boy's)
'22 Yam YZ125X (youngest boy's)
'17 Yam YZ85 (soon to be FOR SALE)
'10 Honda Recon (wife's)
'08 Kaw KX65 (Sold)
'07 KTM 50SX Sr. (Sold)
'09 Yam PW50 (retired)
'97 Kaw KX250 (Sold)

Gallery

2005 KDX200 Bike Profile
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

doakley, you sounded like a chemist!

I cheat and just laid it over sideways until it came out of the overflow tube, then cranked it up and ran it until it was about empty.

Leaving fuel in a clear tank scares me just to read it. :-) I have seen some KDX tanks that have a lovely shade of moss green / brown as they have had gas for years.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
User avatar
doakley
Gold Member
Gold Member
Posts: 1241
Joined: 02:58 pm Mar 10 2016
Country:

Re: New gas tank from Clark MFG

Post by doakley »

KDXGarage wrote: 04:03 am Jan 03 2021 doakley, you sounded like a chemist!
It's been a long time since I made my living as such, but the basics haven't changed.
Toonces
Member
Posts: 19
Joined: 04:19 pm Sep 21 2017
Country: USA

Re: New gas tank from Clark MFG

Post by Toonces »

KDXGarage wrote: 02:04 pm Jan 02 2021 Toonces, those repairs look heavy duty!

What did that cost?
Repair was $80. I told the plastic welder guy that I didn't care about cosmetics and durability was top priority.
I went riding yesterday and another small lead started. I'm going to keep bugging Clarke till they make a tank. I don't think they have any idea about how many people could use a new tank and that they would be the only supplier in the world for this particular tank.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

Thanks for the reply. Sorry to hear that it has started a new leak.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Toonces
Member
Posts: 19
Joined: 04:19 pm Sep 21 2017
Country: USA

Re: New gas tank from Clark MFG

Post by Toonces »

Hmm... It's February. Time to call Clarke again. They are either going to tell me to F@%k off or, make a tank for the E model. Perhaps they'll do both : )
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

There are a couple that sold on ebay. Are you only wanting new and not used?
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Shangrila
Member
Posts: 2
Joined: 04:03 pm Jan 02 2022
Country: USA

Re: New gas tank from Clark MFG

Post by Shangrila »

I've got a large crack on my 1991 200 fuel tank. I have heard tales of using a kx500 tank. I have no problem welding new mounts and modifying mounts as the bike runs like a champ. I picked it up so the kiddo could get experience riding and not tear up a newer bike. I didn't realize getting a replacement tank would be so tough.
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: New gas tank from Clark MFG

Post by KDXGarage »

Are there no used tanks on eBay?
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Post Reply