sir dabs alot Posted March 18, 2006 Report Share Posted March 18, 2006 I have an '02 Sherco 2.9 that I bought used. The fuel tank leaks where the petcock block attatches to the fuel tank. This is differnet than some of the later models so it must have been problematic. Right now I have it fixed with a plastic repair kit that is basically some sort of plastic epoxy. It is holding for now but I would like to find a more permanent fix if anyone knows of one. Thanks, SDA Quote Link to comment Share on other sites More sharing options...
copemech Posted March 18, 2006 Report Share Posted March 18, 2006 I understand that that was an issue on the '02 bike. Personally, I would call Ryan Young and ask him about it to see if he has a preferred method of repair. The only other thing I know is some expensive aircraft fuel tank sealer that should work, It's called "black crap" for a reason! MC Quote Link to comment Share on other sites More sharing options...
scrappington Posted March 18, 2006 Report Share Posted March 18, 2006 The 02 shercos have an o ring where the tap fits the tank,it could be a perished ring or just badly seated. Quote Link to comment Share on other sites More sharing options...
alan bechard Posted March 18, 2006 Report Share Posted March 18, 2006 There were a couple of issues in there with the tank. First, do you have a gasket where the petcock mounts to the tank or just the o-ring. There is a gasket available, that came out after the 02's I believe that will help a lot of them. Second, it is tough sometimes, but you need to ascertain exactly where it is leaking, some leak around the petcock mount to the inserted plastic block, (gasket - o-ring problem) and on some, the inserted plastic block itself leaks where it is bonded to the tank material itself. If you take your tank off, clean it up, and gently wiggle the petcock, you should be able to determine where the problem is. The gasket / rubber piece 99% of the time quikly and efficiently repairs it if it is the petcock leaking where it mates with the inserted plug. If the inserted plug is leaking, I have had the best results by slowly wiggling the petcock to thouroughly break the bond between the insert and the tank itself. It is kind of like pulling a tooth. You want to keep wiggling it till it slowly breaks the bond and comes out of the socket. Do not use force or you are likely to break the tank. After it is out you will want to thoroughly clean and remove all residue, then I would roughen with some 80 grit abrasive, both the cavity and the mating surface of plug, insuring that everything was absolutely spotless. Go to your local auto repair parts supplier and ask for a plastic tank repair kit. It will say right on it not to be used for Fuel tanks. Nobody wants to face the liability of repairing fuel tanks, and the material used in the manufacture of these tanks is not generally considered bondable by the plastics industry. So get one of these kits, over here they are about $8, and avialable from a variety of sources, read the instructions several times, insure that you have everything spotlessly clean, and have dry fit the plug several times so that you know how it should go in. Following label directions, reglue your plug into the cavity. Some of these use a primer then an adhesive. Follow the directions. Then add the gasket and o-ring and reassemble your tank. If you do it this way, it will bond and seal well. Glue smeared on top of the joint comes off and does not seal. RTV is generally not fuel resistant and will peel off the plastic. Good luck, and it is straight forward to repair, but this is one that really pays to do it right the first time. Quote Link to comment Share on other sites More sharing options...
sir dabs alot Posted March 19, 2006 Author Report Share Posted March 19, 2006 The leak is at the block/tank adjoining area. I'm using the plastic tank repair kit with some success. I have it on the seam though and didn't go the "tooth pulling" route. If this doesn't hold, I'll try that next. The palstic repir kit seems O.K. on the seam until it is moved enough to crack the sealer/repair goo. It get pretty hard and brittle once dry. I guess I'll try the "black crap" trick once I get frustrated with this fix. There is an airport local to me here that may offer some assistance. Thanks for the advise, any more is welcomed. Quote Link to comment Share on other sites More sharing options...
wayne thais Posted March 20, 2006 Report Share Posted March 20, 2006 Sherco offers the later model fuel tank in a clear unpainted version. I had the same problem, tried the auto gas tank sealer and it kept leaking. I did not try Alans method. The clear fuel tank price was less than the painted one. I installed "05" graphics on the tank and it looks really good. If you decide to make this update you will also have to purchase a new fuel valve. Wayne Quote Link to comment Share on other sites More sharing options...
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