2009 M1000 cracked gas tank - plastic weld or other ideas?

[dodgedart68]

First, I apologize if this has been discussed before. Anyone have any experience plastic welding the cracked filler necks on these sleds? Or any suggestions on how to fix it? I do have some feelers out for some used ones, but would like to try to fix mine also.

Thanks!

DUSTIN

 

[Steve Friebe]

First, I apologize if this has been discussed before. Anyone have any experience plastic welding the cracked filler necks on these sleds? Or any suggestions on how to fix it? I do have some feelers out for some used ones, but would like to try to fix mine also.

Thanks!

DUSTIN

Trailtank.com has tanks and filter neck repair kits

 

[Sheetmetalfab]

Sticky's polybonder works well on gas tanks.

 

[IDspud]

There is a service bulletin out on these. Last one I had the dealer was required to replace for free.
Parts and labor, way past warranty.

 

[dodgedart68]

Thanks everyone! I ordered a new tank off of Trailtank. I am going to try to repair the one I have also, I'll see how it turns out. haha

 

[boondocker97]

I've seen some people use black zip ties as filler material when plastic welding these.

 

[boondocker97]

There is a service bulletin out on these. Last one I had the dealer was required to replace for free.
Parts and labor, way past warranty.

My dad had one replaced this way a couple years ago. I think they honored it up until there were no more tanks available.

 

[Coldfinger]

Some people have used filler necks for race vehicles. PRP makes one. There are probably others. Not my sled in the pic.

 

[Dakota 1222]

I used gorilla epoxy on both of my m1000 six years and still good

 

[hennmann]

There is a service bulletin out on these. Last one I had the dealer was required to replace for free.
Parts and labor, way past warranty.

Sounds like something to look into because a busted fuel tank doesn't sound good at all!

 

[Readymedic]

Two part epoxy works great! Tightness of the fuel cap is important.

 

[meierjn]

Cat wouldn't replace mine under warranty. After trying various epoxies with no luck I finally bought a used tank and had it installed. I saved the old tank and am going to try my plastic welding skills and see if I can fix it.

 

[Readymedic]

You always have to ruff the plastic up for any glue to stick. A smooth surface will not work. Mine cracked also, been 3 seasons now and is still holding great!

 

[FlynHigh]

There is a service bulletin out on these. Last one I had the dealer was required to replace for free.
Parts and labor, way past warranty.

That was true until COVID then the gas tank supplier went out of business and Arctic Cat couldn’t get tanks anymore.

 

[FlynHigh]

I've seen some people use black zip ties as filler material when plastic welding these

If I remember right the tanks are made out of HDPE. Look around for any other piece of plastic that is marked as being made from HDPE. Cut some off to use as a filler material. That is what I did along with using some stainless steel mesh that is like heavy duty window screen. I did that to a sled. Worked good for the two years I had it. Couple theories on why they crack is “hanging” the gas nozzle on it or over tightening it.