IMS fuel tank drain plug bung stripped - Kawasaki KLR 650 Forum
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post #1 of 32 Old 05-11-2020, 12:41 PM Thread Starter
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IMS fuel tank drain plug bung stripped

Attempting to drain my IMS 10 gal tank and the drain bung spins in the tank...(on both sides!) So just to be more clear, the drain plug and bung are turning together - looks like the bung is a brass hex that is cast into the poly tank.
Anyone run into this?

When I get them apart, I wonder how well (or not) a hot glue "weld" would work.
What would you guys do?
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Last edited by alphashifter; 05-11-2020 at 01:05 PM. Reason: Clarity
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post #2 of 32 Old 05-11-2020, 01:21 PM
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I'll suggest that someone put thread locker on the brass bung & it has more grip on the brass bung that the plastic had.

Sorry to say that you are probably 'bunged' forever and the bungs will now probably leak like a sieve. Teflon thread tape would have been more appropriate.

People accidentally permanently attach the plastic radiator shrouds onto Gen2 rubber well nuts and onto real dirt bikes on a regular basis by using Loc-Tite in places that it should NEVER be Used.
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post #3 of 32 Old 05-11-2020, 01:31 PM Thread Starter
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Originally Posted by pdwestman View Post
I'll suggest that someone put thread locker on the brass bung & it has more grip on the brass bung that the plastic had.

Sorry to say that you are probably 'bunged' forever and the bungs will now probably leak like a sieve. Teflon thread tape would have been more appropriate.
"Bunged"
Yeah, that sounds reasonable since both of 'em are "screwed". I think the PO did both tape and loctite since I think I see some teflon tape poking out on one of them.

If anyone has successfully repaired such a goof, I'm all ears - Lotta things I'd rather spend money on than a new tank.

I'm thinking a glue gun is at least worth a shot...Will post results.

Last edited by alphashifter; 05-11-2020 at 01:56 PM. Reason: Added comment
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post #4 of 32 Old 05-11-2020, 03:56 PM
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just spit balling... maybe clean it all out, bolts, bungs and fuel then pack JB Weld in there til it fills the void and hope like hell that it seals off from fuel forever???

sre
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post #5 of 32 Old 05-11-2020, 04:02 PM Thread Starter
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just spit balling... maybe clean it all out, bolts, bungs and fuel then pack JB Weld in there til it fills the void and hope like hell that it seals off from fuel forever???
Yep, I'm thinking something like that - Plastic weld or something.

For anyone following, interested or facing the same thing, here's something fairly promising -
https://youtu.be/CE1iNRhIGxY
Speed video to 2x and you get the idea.
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post #6 of 32 Old 05-11-2020, 06:54 PM
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You may want to look in the phone book for a shop that does actual plastic welding. Bumper shops may be a good place to start. Otherwise try contacting IMS to see if they sell repair kits.
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post #7 of 32 Old 05-16-2020, 10:41 PM Thread Starter
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Got the bungs out, but two of the cap bolts have become un-bonded as well. I cut them off and the remaining studs are proving much trickier to get out than the bungs were. The previous maintainer definitely used some sort of thread sealant on the bungs, and I'm thinking he/she did on the cap assy too.
Tried a heat gun and gently pulling the nuts out of their sockets, but it was causing a lot of distortion to the cap opening so I went back to the drawing board.

Anybody have ideas on something that might penetrate and soften thread sealant? I have some gasket remover on them now. Will post results.
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post #8 of 32 Old 05-17-2020, 09:00 AM
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A desperate lunge, perhaps, but . . . why not contact IMS customer service regarding repair kits (if any, as mentioned above), and even . . . possibility of sending the tank back to the factory for repair. The latter, an expensive approach, but . . . maybe more affordable than a new IMS tank.

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post #9 of 32 Old 05-17-2020, 10:08 AM Thread Starter
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Originally Posted by Damocles View Post
A desperate lunge, perhaps, but . . . why not contact IMS customer service regarding repair kits (if any, as mentioned above), and even . . . possibility of sending the tank back to the factory for repair. The latter, an expensive approach, but . . . maybe more affordable than a new IMS tank.
You guys are right: I should give it a shot and find out for myself what their support is like.

Was thinking I'd try the sometimes-successful JB Plastic Weld repair with some All-Seal. Still may, depending on what I find out from IMS.

I always carry a spare vacuum pump rebuild kit with me, and what I realized this time was - that would have been moot if I couldn't get into my tank on some eternal dirt road deep on the reservation. So for that reason, I may look for used parts and go back to stock.

Last edited by alphashifter; 05-17-2020 at 10:09 AM. Reason: clarity
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post #10 of 32 Old 05-17-2020, 07:45 PM
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Originally Posted by alphashifter View Post
You guys are right: I should give it a shot and find out for myself what their support is like.

Was thinking I'd try the sometimes-successful JB Plastic Weld repair with some All-Seal. Still may, depending on what I find out from IMS.

I always carry a spare vacuum pump rebuild kit with me, and what I realized this time was - that would have been moot if I couldn't get into my tank on some eternal dirt road deep on the reservation. So for that reason, I may look for used parts and go back to stock.
I went with a 6.6gal on mine after trying the 10gal for a number of months. Just too much of a headache and nothing fits it (crash bars in particular)
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