[thelonegoose]

So I was gifted a 2006 honda recon 250 that had been sitting for a few years. I figured ill flush out the tank, change some hoses, and the carburetor and go from there. When I got the fuel tank off one of the nuts in that holds the bolts for the petcock was stripped. I looked at a diagram and cannot seem to properly identify the exact part I need. It is the nut type brass piece that sits up in the fuel tank that the petcock screws into. Any help would be greatly appreciated. I will try to post a picture in the am.

 

[retro]

It sounds like the threads are stripped out of the collar? Number 11 (number 24 is the petcock bolt) on this parts fiche:

Honda ATV Parts 2006 TRX250TM A FUEL TANK Diagram

Welcome to the forums!

 

[thelonegoose]

It sounds like the threads are stripped out of the collar? Number 11 (number 24 is the petcock bolt) on this parts fiche:

Honda ATV Parts 2006 TRX250TM A FUEL TANK Diagram

Welcome to the forums!

Appreciate the welcome! I dont think it is the collar. I dont think the collar is threaded. Its the brass piece that sits below the collar that the bolt screws into. It sets in a cut out of the fuel tank.

 

[retro]

OK, that leaves you two choices. Either replace the tank or drill & tap new threads into the retainer. It is a 6mm bolt now, so the next common metric bolt size would be 8mm, which is probably going to be way too big. I would run a 1/4" SAE tap in there and see if you can get good enough threads cut to thread into using a 1/4" stud. If that works, screw a stud (of sufficient length) into it with JB-weld original formula epoxy coating the threads and wait for 24-36 hours for it to cure. If you use ethanol laced gas in your bike, you'll have to allow 48-72 hours of cure time. Don't rush it or you'll be buying another tank. When its ready, put it together and fill it with fresh gas & go.

Enjoy your work!

 

[retro]

The reason tapping the hole to use a 1/4" stud might work, is the size difference between a 6mm bolt (0.2362") and a 1/4" bolt (0.250") is about 1/64" larger. Those new threads will be thin and fragile... won't hold much. So, use the good stuff (JB-weld original) to anchor a stud in there. You'll be a winner if you use the original slow-setting stuff and allow it to cure fully... plus some. Ethanol will dissolve it if you don't allow it to fully cure.

 

[thelonegoose]

OK, that leaves you two choices. Either replace the tank or drill & tap new threads into the retainer. It is a 6mm bolt now, so the next common metric bolt size would be 8mm, which is probably going to be way too big. I would run a 1/4" SAE tap in there and see if you can get good enough threads cut to thread into using a 1/4" stud. If that works, screw a stud (of sufficient length) into it with JB-weld original formula epoxy coating the threads and wait for 24-36 hours for it to cure. If you use ethanol laced gas in your bike, you'll have to allow 48-72 hours of cure time. Don't rush it or you'll be buying another tank. When its ready, put it together and fill it with fresh gas & go.

Enjoy your work!

Considering the price of a new tank, I will try the cheaper fix first. It can't hurt anything at this point. I didn't even think to drill and tap. Appreciate the input.

 

[retro]

One more bit of advice that will save you a lot of time and money: When you begin work on your carb don't buy a cheap china knockoff kit for it. Just take it apart completely and clean it thoroughly, then reassemble it to specs exactly, step-by-step, as the service manual recommends. Adjust the cables like the manual says to when you put the carb back on the motor. If you do everything well you probably won't have to spend a nickel on parts. If you do buy a kit, buy OEM Honda only. Everything else for sale nowadays is useless china garbage.

You can get a copy of the service manual HERE.

Have fun,

 

[retro]

Considering the price of a new tank, I will try the cheaper fix first. It can't hurt anything at this point. I didn't even think to drill and tap. Appreciate the input.

Don't drill it out first or you'll remove your advantage!!! Just run a 1/4" tap through it, as is.

 

[thelonegoose]

I've already got the service manual downloaded. I was planning to just take apart the Carb and cleaning it. I dont think it will need replacing.