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Gas Tank cracking KDX220 2001
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Posted by: JimVowell---------------------

Anyone else having trouble with their Gas Tank cracking under the cap. Ive have bikes for over 20 years and never had this problem. Seems like a factory defect....

Posted by: someday---------------------

Common - do a search.

Posted by: jimicarl---------------------

my 99 kdx220 "gouge", had the left-side top radiator shroud plug pulled out (corn-holed an XR650 on a muddy hillclimb last spring), but no cracking! the plug welded right back in with no huge problem, and has been snug through a number of crashes. and..., it didn't leak through the plug hole, so i was able to complete the ride that day!

i searched for a replacement tank when it happened 'cause i wasn't sure if it was gonna leak or if i'd be able to replace the plug. interesting to note that clarke doesn't make a tank for newer model kdx's. if you're looking for a replacement after-market tank..., i think you're pretty much stuck with IMS.

have fun!

Posted by: dhoward---------------------

There have been a lot of reports on this board regarding tanks cracking around the filler neck. As I recall, they were repaired under warranty.

Posted by: JimVowell---------------------

Thanks, I may be out of warranty now...but good info....

Posted by: dhoward---------------------

I seem to recall Kawasaki taking care of these problems even after the standard warranty expired. You might check with your dealer. Seems pretty dangerous to me what with gas leaking all around your goodies and all....

Posted by: dkb---------------------

Jim I have the same problem on my 00 220. My local dealer was no help. So I called Kaw. consumer dep. and they said tell your dealer to call the 1800 hot line I asked for the hot line number ,but didn't get it. Several people on this site have gotten ther tank replaced. I have not had such good luck

Let me know if you get any better results

Posted by: NDRO---------------------

I would mention the fact that it's a safety issue and Kawasaki has replaced others, when out of warranty, because of this...

Now to keep my 99 from doing it...:scream:

Posted by: someday---------------------

After my local dealer, who I DID buy the bike from, acted totally disinterested after a couple weeks of patience on my part I called Kawasaki's Consumer Help 800 number. The guy who answered made note of my problem, acknowledged it was common, gave me a service/work order number, then told me to go back to the dealer with this number and have them call Kawa tech. That's the secret 800 no. dealers only have. I can probably dig up the letter I wrote to my dealer that has a contact name at Kawa and so forth on it. I'll email it to you if interested. Ask me at jeffd@plowhearth.com. Got mine replaced out of warranty a couple weeks ago.

Posted by: BIGFOOT16---------------------

What do you know;just checked my 2001 220 tank neck and it is cracked.Does anyone know for sure if Kaw is replacing the tanks under some sort of recall?Maybe we all need to call or e-mail the same dept. at Kaw so they are more aware of the problem.I honestly EXPECT them to replace it for free.I am also considering selling the bike to avoid any other headaches.

Posted by: JimVowell---------------------

Ok, so check this out. I went to the dealer. The service manager said that I had to call Kawasaki and get there authorization and then they would call him back and replace the tank. So I call Kawasaki and they told me that the service manager is supposed to call the Hotline (some dealer only number) and talk to them about getting it fixed. I find it hard to believe the SM did not know that to begin with...The dealers closed today so I let yall know what happens tomorrow when I talk to the genius (SM) at the shop. GEEEEZZZZZZ.....

Posted by: BIGFOOT16---------------------

I called Kawasaki this morning and they said to take it to my dealer for a "good will waranty" check.My dealer(TUF Racing)looked at it and said he would order me a new one right away.No charge!!Kawasaki will cover the replacement as long as it's not from a crash.

Posted by: dkb---------------------

Same story here. Thanks to someday, I also have a new tank on the way

Posted by: someday---------------------

Hoowah! The little guy gets his due for a change

Posted by: KEONDGO---------------------

i called Kawasaki first, they said it sounded like something that they would help me out with and told me to go to my dealer and have them call their number. i did, my dealer called and not only did i get the tank but they even gave me new graphics on my 01 kdx 220. this is why i have a kawasaki dirt bike and jet ski.

Posted by: BIGFOOT16---------------------

Glad to hear about the tank!!Why did you get new graphics?

Posted by: JimVowell---------------------

Hey DKB any luck yet. im still getting jacked around by kawasaki and my dealer......

Posted by: dkb---------------------

Jim my dealer ordered a new tank for me. No charge

I don't understand why your dealer hasn' called the hot line and got you one ordered:think Good luck Darin

Posted by: KDX'r in IN---------------------

:silly: same old same old....new tank on the way (thanks to Kawasaki)

Posted by: JimVowell---------------------

Good news, the dealer finally came through a tank is on order. Thanks for all the help...........

Posted by: BIGFOOT16---------------------

Mine was ordered,last Monday.Any idea as to how long it takes for the replacement?Also,I'm hoping that the new one does not come from the same batch!

Posted by: dkb---------------------

BIGFOOT16 My kaw. shop called today and told me my tank was in. It took about a week and a half

Posted by: dkb---------------------

My wife went to pick up my new tank today. I had to work and didn't know she was going. So... I drive there after I got back from the job site. I walk in and they ask if I brought my old tank? Long story short we both drove 25miles and my tank is still at the shop. These people know me and my kids by name. and are still worried that I won' t bring the old tank back:silly: I have never wronged this shop ever. Just seems lame to me. So take your old cracked tanks to get your new one.:D

Posted by: someday---------------------

This had been linerging in my mind as a possibility, but you know what SUCKS - my "new" tank is cracked now too! Monday begins WWII (diplomatically of course) on Kawa and my dealer. Tomorrow's race is much more important now

though. Will keep all posted.

J

Posted by: BIGFOOT16---------------------

That was my fear too!!Keep us posted and good luck.

Posted by: someday---------------------

My son did well in today's race, I chickened out. Got some good photos tho! Dealer's my first call when I get to work tomorrow.

J

Posted by: someday---------------------

Spoke with Rick again at Kawa Customer Service. No problem getting me a second tank, dealer already has it on order. The BEST news is that Kawa has superceeded the old tank to the 2002 tank which they claim is a different plastic compound. The part number for the 2002 tank is 51001-1668-6W. Make sure that's the one you get should you need one in the future.

J

Posted by: BIGFOOT16---------------------

Got my new tank today!!!Too bad,it's the old part number.I hope I don't have the same problem again.But,a new tank every six months,makes me feel like a factory sponsored rider!

Posted by: JimVowell---------------------

The new tank is in and I pick it up today. Thanks for all the help yall.......

Posted by: FaTCaT---------------------

well I found mine cracked too today....not all the way through yet but still cracked more then half the way around in 2 different cracks....hope I get the same treatment as you guys...going to call them tomorrow

Posted by: kipmax---------------------

Hmm, I have been riding plastic tanked dirt bikes since... Well, since they started putting plastic tanks on them

and haven't run into this problem until recently. A friend of mine just had to replace the tank on his kid's TTR125 playbike for the same reasons.

Do you suppose the manufacturers have changed the type of plastic? Or, could it be that the gasoline producers are putting in some new funky additive that is causing the problem?

Posted by: JimVowell---------------------

Hey got my tank and it is the old part number. It's pitted big time around the filler cap (not cracked), like there were air bubbles when it was pour into the mold. Im going to try it for a while and hope when it cracks again that KAWA will still honor the replacement (hey at least they came through this time)on an as is product thats pretty cool....

Posted by: FlashBurn---------------------

I have a 2001 KLX300 and the tank on this bike also cracked.Kawasaki replaced it under warrenty within a week.This may sound silly but the oneway inline checkvalve on the gascap hose would not let me blow through it in either direction.Me thinks that the tank may have pressurized and cracked at the weekest point.I cut the oneway valve out of the hose just in case this had anything to do with it.

Prewire

Posted by: JimVowell---------------------

Well the saga continues. My new tank cracked in 3 days. What a piece of ****e...

Posted by: Trigger1911---------------------

Curiosity got the best of me. I looked at the tank on my98 KDX220 and the damned thing is cracked!! Thank you guys! The war starts now!

Posted by: BIGFOOT16---------------------

Checked my replacement tank today after washing my bike.It is cracked too!!!!I am going to the dealer monday,after work and try to get a new one.I heard that the KX'S are having the same problem.THIS IS GETTING REAL OLD!!!

Posted by: assertthis---------------------

I'm waiting on a new tank for my 2001 KDX 220 also. The dealer claimed ignorance on it being a known problem, but I convinced them to ask Kawasaki for a good-will warranty. They agreed. Hopefully the replacement I get won't crack too.
There is no excuse for these tanks. I haven't even crashed the thing yet! I'm such a wussy!

I'll let you guys know how it turns out.
assertthis

Posted by: BIGFOOT16---------------------

I just got back from my dealer.He is going to order another replacement for me.This time,I requested that he order the superceeded part number instead of the regular part.Hopefully this will work.
Also sent a letter to Kawasaki Consumer Relations.My thinking is that this should be a recall,not just a few guys that read this post.
Time will tell.

Posted by: MADisher---------------------

I know assertthis and yes he rides like a girl, he has not harmed his bike in any way... trust me on this.

I also went with him to the dealer, and while I pretty much refuse to buy from them anymore, they acted about like I would suspect. Pretty close to rude.

they claimed 'There is no new part number, Kawasaki has reinforced the tank'.

We were wondering though what year they put the checkvalve on the vent hose ? Do you think the pressure that can build in the tank with a checkvalve could cause any of this ? Are the older tanks just as weak in that area but don't suffer the cracks because we don't have said checkvalve ?

-MD

Posted by: BIGFOOT16---------------------

The new part number was posted earlier in this thread.It is 51001-1668-6W.
When I went to my dealer today,I requested that he order the new number.So far,both my dealer(TUF RACING)and Kawasaki have been good about replacing the defective tanks.It's just a pain in the A##,to keep running down there.
I'm sure that their getting sick of seeing me ,too!!
Still love the way my KDX performs.

Posted by: RTL---------------------

I noticed a crack around my tank filler neck today. The crack went 3/4 around the filler neck and was pretty noticable..

Called the Kawi Cust Serv number, got a call reference number, and was directed to take my bike to my local dealer for inspection. Service guy at the dealership inspected and called Kawi while I was waiting... Kawi authorized a full replacement..

My new tank should be here in a week or so.. So far, not a hassle one.

They even gave me my choice of green or black, I selected black.

I will follow up once I actually have my new tank in hand, but I wanted to add my bike to the list of many who have had their tanks replaced. The threads here on this forum made my plan of action a breeze.. Very helpful, as usual. Nice job everyone!

Posted by: skipro3---------------------

Could you please post the Kawi Cust Serv number here? I would like to call and get a reference # as well.

Posted by: RTL---------------------

I got the Customer Service number off of the Kawi website.

949-460-5688

Posted by: KelvinKDX---------------------

Quote:

Originally Posted by RTL

I got the Customer Service number off of the Kawi website.

949-460-5688

This information should be put in the KDX FAQ.

Posted by: skipro3---------------------

Thanks! My tank will be ordered today once the dealer confirms he can get me a black one. (My preferance) He seems to think I won't be able to due to authorization by part #.

Posted by: RTL---------------------

Well, after waiting several weeks for the black tank to make it's way out of backorder status, it has arrived. I installed it this moring.. Looks darn good.

Kawi came through for me with no hassles, even with the black tank.

Green's Kawasaki in Oak Ridge TN gave me no hassles and seemed glad to help me out as well.

That is the way customer service is supposed to be, my props to both parties.

Posted by: JasonWho---------------------

---

Posted by: skipro3---------------------

I got mine in last week. My local dealer was a real stinker in helping me though. He kept telling me there would be no way Kawasaki would warrantee the cracked tank. He said it was due to a fall onto a rock or something. I had to provide photo copies of my registration and title. Since I was not the orgional owner, he said that Kawasaki was balking. Then he called one day last week and said it was in. He also told me he would not give me a black tank because the part # is different than the part # Kawasaki authorized him to order as a replacement.

Posted by: Knobbyjake---------------------

Skipro, I'd find a new dealer. Yours sounds like a real piece of work.

Posted by: skipro3---------------------

Yup, a REAL piece alright. It seems like every time I go in there, it's like they are on the defensive and are prepared to go toe to toe with the customer instead of standing shoulder to shoulder. Not just me, I notice their treatment of other customers as well. As I was waiting my turn to be served when I went in to pick up my tank, the owner was finalizing the paperwork for a little offroad motorcycle to some kid and his divorced mother. It was obvious as they showed little Johnny how to work the throttle and clutch, this kid had not a clue about anything with a 2 stroke bike. He won't be able to start it and even if he does, I'm quite sure he won't do the premix correctly. Mom also bought MX boots for him. As the bike was loaded into the trunk of their car, little Johnny pointed out that a buckle on the boot was defective. The owner told them to contact the manufacturer. It's 75 miles round trip for me to the next Kawasaki dealer. I won't be back into this one, that's for sure.

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Gas Tank cracking KDX220 2001

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