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Old 12-24-2011, 06:05 PM   #1
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03 ZR 900, Cracked Filler Neck. Epoxy? Plastic Weld? What is the tank made of???

I picked up a used 03 ZR 900. The guy told me the tank was cracked around the filler neck/cap area but he epoxied it and it was sealed. Its not sealed. I am trying to weigh my options right now on what the best route will be.

I saw some posts where a plastic tank repair kit from Autozone worked on a tank where the pump neck had cracked.

I was thinking also just using some Plastic Epoxy.

My ultimate thought was to Plastic Weld the tank. I am not sure what type of plastic these sled tanks are made of but I have heard before the only way plastic welding works is if your use sticks of the same type of plastic. i./e ABS, Urethane, PS, Polypropylene....

Can anyone get me point in the right direction???
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Old 12-24-2011, 09:08 PM   #2
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From everything I have been reading fuel tanks are made from polyethethylene. A plastic that is almost impossible to repair with glues and epoxies.

I guess about the only way to fix it is with heat. Which obviously is a HUGE risk when its a fuel tank. I am almost thinking it would be easier to just buy a new tank, but if I had a plastic welder it would be worth a try.
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Old 12-25-2011, 12:40 AM   #3
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I've plastic welded them. Used the following filler rod in the plastic welder. Also used it to repair a hood almost completely broken in two up by the front bumper. The support cable gave out and the hood went all the way over and broke about 90% of the way by the hinge. Plastic welded it with the fiberflex rod 2 years ago and have not had a problem since. The tank neck repair I did was on a 98 ZR 600 and that was about 6 years ago. Still holding up, but me and the guy that bought it from me are careful not to torque the cap too much. If you still want to use the exact same rod as the tank is made of then you can use the second link to aid in identifying the material.

FiberFlex Flat Sticks, 30 ft. | FiberFlex

Plastic welding made easy by identifying plastics!
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Old 12-25-2011, 01:15 AM   #4
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Oh yeah. I have heard that the filler necks on some models are made of a somewhat different material than the rest of the tank and molded into the tank that way during manufacture. I believe the info I read said the filler neck was a stiffer material and less flexible than the rest of the tank. The crack I fixed was right in the corner where the neck meets the tank and was about 1 to 1-1/2 inches long. I put a generous fillet of material in and it didn't interfe with the cap. I had drained the tank and rinsed with water before attempting the repair and after the repair spent a good amount of time insuring all the water was out.
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Old 12-25-2011, 07:17 AM   #5
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Thats a million for that knowledge. I would have to believe they are different materials as well. Mine is cracked right in the corner where it meets the tank as well. And the way it is cracked around the neck, its a perfect line. Like a seam.

Did you actually remove the tank from the sled?
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Old 12-25-2011, 07:38 AM   #6
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Old 12-25-2011, 07:27 PM   #7
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id check with you dealer i know there was quite a few different sleds in 03/04 with a recal on that exact problem....
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Old 12-25-2011, 09:01 PM   #8
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 Quote: Originally Posted by mainegreen420 View Post
id check with you dealer i know there was quite a few different sleds in 03/04 with a recal on that exact problem....
I appreciate that thought.. I will check into that.
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Old 12-25-2011, 09:33 PM   #9
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I did the same thing with my ZR it was cracked around the neck and tried using everything to fix it. Finally said screw it drained the gas out of it and heated up a screw driver and melted the inside and outside back together. It has been 4 years and it is still holding up strong.
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Old 12-25-2011, 09:47 PM   #10
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Arrow Plastic Repair

I've used with great success a product out of Canada called, "PolyAll 2000". I have repaired snowmobile and ATV fuel tanks with it.
It sets up quickly so have it all figured out before you start.
It's not cheap but it works.
Here is the link: http://www.polyall.com

Another product that works great to repair body parts is called, "Three Bond Plastic Repair Kit". You can get this through any Parts Unlimited Dealer.

I use both these products all the time to make repairs and they both work.

Greg
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