IMPORTANT - 250R Tank - Clark - WARNING

[atctim]

This is a big heads up. I've never heard of this issue before, and can not believe it is manufactured in this way, but I want to get the word out. I recently purchased an 85 / 86 ATC250R Clark tank. There was a little fitment issue. When I would bolt the front of the tank to the frame, the rear "ear" holes (at location of front seat latch) were about 1/2" off - to far forward. I tried to pull, stretch, pry the tank back so the holes would line up with no luck. So I drilled out the metal bushings, and egged the holes out. Now it fit. I carefully mounted the petcock, and it was then time to fill the tank with some petro to be sure the petcock seal was good. With some pre-mix in the tank, the petcock was not leaking, then a rush of gas started flowing onto the ground. The petcock was off, so I knew it was not from the carb. Low and behold, where I egged out the ears on the back of the tank - gas was gushing out.

NOTE TO ALL - do not egg out rear ear mount holes on Clark ATC 250R tanks. There is a hollow cavity around the bolt holes!!!!! (this may or may not be the case with Stock tanks, although stock tanks should not have fitment issues as aftermarket tanks may)

I carefully took my grinder and chopped out a 90 degree notch to expose the cavities around the mount holes at 12 and 3 o'clock and 12 and 9 o'clock respectively (right and left side).

I now need to find a gasoline resistant epoxy or silicon to seal these holes. Then when I mount that back of the tank it will have to be a "pinch" mount rather than a hole mount.......... What a nightmare!!!!!!!!!!

[El Camexican]

Has anyone out there ever bought a Clark tank that just bolted on? I know I've never seen one.

[Escanabajosh]

http://www.amazon.com/SEAL-ALL-2-OZ/dp/B0017M44Q6

not sure on plastic but this stuff worked good on my old car tanks

[Blown 331]

Do you have any pics of this? I can't seem to picture what you are describing. The rear of the stock tank bolts on through aluminum, are you saying the Clarke tank mounts through plastic?

[Mr. Clean]

I just finished up a 250r tank last night. I assume you need this for TF2012. If you need it I can get it in the mail today......well Mrs. Clean can get it in the mail today!! I also have an oversized tank in the classifieds.

[ONEBAD350X]

wow that sucks. Thanks for the heads up. I hope you get it fixed.

[3wheelrider]

I have brought this up a here a few times when a 250r clarke tank is discussed. I never got a response or reply with others having a problem ever. Clarke of course says the same. I Had the exact same issue on 2 new white 250r tanks bought a few years back- many months apart. A new tank should just bolt on. I had to modify both tanks (front mounts) to get the bolts to go thru. No amount of prying or pulling would make the holes line up. Not your fault. They don't test fit the final product I guess. And that hollow section around the rear bolt holes really was a sucky idea. Oh yeah the gas cap seal lasted about 2 months before it crumbled into the tank. Also the area where the seal rides against (on the tank) is really thin,-not much sealing area. -I believe the newer CR gas caps fit. Sorry to hear about that.

[El Camexican]

I have brought this up a here a few times when a 250r clarke tank is discussed. I never got a response or reply with others having a problem ever. Clarke of course says the same.

My oversized Clark tank for my KTM required the following mods to fit:

- Drill out the petcock filter hole
- Drill out the mount holes on the stock petcock base to allow it to match the threaded inserts on the tank which were 3/16” farther apart than the stock tank
- Drill out a crooked petcock insert and re-tap it
- Grind the stock seatpan mount to allow for the misplaced tab on the Clark tank
- Install two “dummy” bolts in my rad shrouds as Clark felt it was unnecessary to add threaded inserts in those locations.

I called them when I realized the petcock was not going to bolt on and got the canned “We’ve NEVER had a complain about this before”

Aside from that it was a snug fit to the frame, which is fine, it has an awesome oversized fill cap and it looks pretty good, but if you aren’t a do it yourselfer this is not the tank for you. It also covers the radiator bleed screw, so you have to remove or lift the tank with the bike running to bleed the right side rad.

[Flossyb20]

I now need to find a gasoline resistant epoxy or silicon to seal these holes

MarineTex is what you need...go to any boat store and they'll have it.

[atctim]

I went to a local parts store and bought JB Water Weld. It is JB weld designed for liquids. Resistant with gas, oil, hydraulic fluid, water, liquids, and bonds to plastic, brass metal, etc. I'll post up later when I see if it holds gas.

[fire1]

Thanks for the info I was getting ready to a order a white Clark 250r tank now I'm concerned

[atctim]

I have always called my orders in. May try the same, tell them you know folks who have ordered and have fitment issues, and see what their return policy is if they don't fit. other than the fitment issues, their tanks look great. I knew up front I could not return as I ordered a non-typical color. I think red, black and white are all normal stock colors.

[Blown 331]

What color did you get? Hopefully your repair will work. I haven't seen much success with repairs similar to this. I'd be curious on the long term durability.

[atc007]

Boy,,this seems so simple to me. Send them all of their non fitting garbage back and get a refund. This is absolutely unacceptable. Unless they come with the sales pitch that they WILL NOT FIT THE MACHINE YOU ARE BUYING IT FOR.

[dcreel]

Boy,,this seems so simple to me. Send them all of their non fitting garbage back and get a refund. This is absolutely unacceptable. Unless they come with the sales pitch that they WILL NOT FIT THE MACHINE YOU ARE BUYING IT FOR.

Don't forget you have to pay to ship it back, and the restocking fee. Been there done that. Clarke will never see another dime of my money.