HELP! 2005 KDX gas tank removal

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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Norm 427
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HELP! 2005 KDX gas tank removal

Post by Norm 427 »

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!
Last edited by Norm 427 on 10:17 am Oct 14 2017, edited 1 time in total.
Dekon
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HELP! 2005 KDX gas tank removal

Post by Dekon »

Sounds like they are stripped.
bzdang
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Re: HELP! 2005 KDX gas tank removal

Post by bzdang »

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...
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doakley
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Re: HELP! 2005 KDX gas tank removal

Post by doakley »

I got mine out with an air wrench. Always use generous antiseize afterwards and haven't had any further problem.
Norm 427
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HELP! 2005 KDX gas tank removal

Post by Norm 427 »

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.
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Tyl3r
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HELP! 2005 KDX gas tank removal

Post by Tyl3r »

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!
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John_S
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Re: HELP! 2005 KDX gas tank removal

Post by John_S »

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.
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