FX450 2010 model. Punctured fuel tank.

Roland Ooi · Nov 24, 2017

Guys. I use a 2010 model FX450 for my enduro rides. And punctured my fuel tank when I fell onto some rocks.
Now I can either try to patch it (which I have and failed on about 3 attempts) or find a replacement.
Is anyone here breaking an FX for parts or does anyone here know where I could get a used one for a good price.
Thanks for all the help.

tourist · Nov 24, 2017

Welcome!

1: It's not easy to patch these tanks because of the polymer material. I do remember some information about materials that could possibly work in threads relating to converting the rear subframe into a fuel tank. You might find it if you search the site.

2: If it helps, I'm pretty sure that any tank across the FE / FX / SM models and 2009-2012 model-years will fit.

Rainerio · Nov 24, 2017

09-12 Only difference with any of the tanks is newer tanks have a low fuel sensor still will work and color.

jon andersson · Nov 25, 2017

This is the only time I heard of a fix of this material:
http://husaberg.org/mechanical/24703-its-official-subframe-tank-100-fixed.html

As tourist says, it's a difficult plastic to work with.

fe390vt · Nov 25, 2017

tank

is it the black tank or clear? i have broken a black one. very difficult to fix, but possible. the clear ones do not break.

fe390vt · Nov 25, 2017

if its black, then west system g-flex epoxy may work with fiberglass. but you have to keep the plastic warm enough that its molecules are still loose for a long period. With the grey/clear material, heat is also very important, both the tank and glue must be warm enough to bond, which may mean throwing your tank in an oven and heating up to 240 fahrenheit. 120c. must also be clean of oils etc. scuffing with 60 grit also helps. I have a spare tank with quick fill. will sell for 300+shipping.

FE350 · Nov 30, 2017

The tank is made from HDPE plastic and is resistant to most chemicals and bonding agents. Try this prior buying a tank it can hurt your damaged tank anyways.
Find an old bottle that has the HDPE recycle emblem it will be a number 2 with a recycle triangle around it. Cut some strips from it as you are using this as the welding stick.
Clean your tank well and of course drain it and air it out so its not a bomb. Clean the area around the crack with sand paper and clean it all with alcohol after, let dry. Find a wide tip solder iron and start to run it down the crack and soften the plastic, make sure you grove the plastic well and get all areas of the tank that are split. Now heat the stick and fill the grove you made. after the grove is all filled than run the iron over the filled area to bond it all together. Take your time and don't be in a rush as the littlest spot that you miss will leak. Hope it works.

Roland Ooi · Jan 15, 2018

Thanks guys. You've been a big help. At least now I have some options on how to deal with the leak. The bike has just developed another problem.....it stalls after about 5 minutes of riding. Kill the engine and fire her up again and the problem is gone.....For about 5 minutes.
My mechanic seem quite sure it's a clogged injector, but in think it fella more like an electrical issue.
Anyway, it's an old bike and it's starting to cost a fair but to keep it running.

383hq · Jan 15, 2018

I punctured a larger safari tank just prior to doing Cape York on a KTM a few years ago.
Nothing up that way so had nothing to loose trying different methods, ended up the first method tried worked very well
I Plastic welded it with a heat gun using cable ties as a filler material.
Worked fantastic, Did 3000 km no problem no leaks.
Will cost you very little to try, just keep the area very clean before hand

FX450 2010 model. Punctured fuel tank.

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Roland Ooi

tourist

Rainerio

jon andersson

fe390vt

fe390vt

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Roland Ooi

383hq

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