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Hi Everyone,



I'm starting a new topic thread to find out who purchase a Clarke tank and whether it fit or not? I just recently received a Clarke tank as a Xmas present and it did not fit my bike which is a '91. I'm not happy that he paid that much money for it and it not fitting. After riding with Jeff yesterday and saw that it fit his bike perfectly. After discussion, we were wondering what year everyone bike is? Maybe there is a difference between the years even though I heard from a lot of people that the TW200 hasn't changed much over the years. So I guess I'm curious to see how many rider got one and what year is their bike?.
 

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It seems the differences are coming from the Clarke tanks and not the TW's. Seems like a manufacturing process(es) are throwing off the end product. Are there multiple molds Clarke is using where one produces a good product and one does not? Is there a specific temperature that the newly molded tanks must reach before being removed from the molds? What happens if that temperature isn't reached, are the newly produced tanks distorting while cooling? Are temperatures at which the tank is stored/shipped/etc. coming into effect at altering the shape of the tank? Are the molds properly designed to deal with thermal expansion? I would hope so, but maybe a newbie designed it incorrectly and it got through the checks and balances without getting caught.



Molds aren't cheap. They may acknowledge a problem internally at Clarke but understand it's too costly to redesign/cut new molds, and that acknowledgement will never come out publicly, but is something we can only hypothesize about.



My limited knowledge says no matter what stock metal tank you find (an '87 or a '95 or an '09) they will all bolt up exactly the same...which should prove that it's not a TW issue, but a Clarke issue.



My 2 cents
 

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Mine is a 2006 TW200 . The right side panel "button" is a little tight, but not a deal breaker.







I am pleased with mine and enjoy the extended range.



 

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On my 2005, the hole for the right side panel on the Clarke tank is about 1/4" off. Enough that the tab on the side panel won't go in the hole in the tank.



Like HenryJ, it's not that big a deal to me. I like the tank, but have used it for only part of one riding season.



I'm more concerned about the durability of the mounting points that Lizrdbrth mentioned. But I'm not losing any sleep over it.







jb
 
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First, thanks for the forum. I just bought an 87 and found on this forum lots of info and confidence in the TW200.

After purchase I found out that I needed a new tank and decided to order a Clark even after reading about fit problems.

The tank does not fit my 1987. The right side is wrong and the plastic does not fit. Looks like I will have to adjust the tank to the right ( mis-align ) and or bend the bolt to install the side cover.



First time poster.

First time TW200 owner.
 

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My Muley is 2007 and the tank fits GREAT!
 

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My 06 the left side fits fine the right side needs a little massage but it will fit, the bike needs a bigger tank if only for looks, but the extra range is great.
 

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Tank fits on my 09 but I had extra side panels so I cut the tit off, drilled a small hole and ran a zip tie thru it. The tank would have had to have moved 3/4" back to line things up but even then the tank grommet is too thick for the side panel to lock into it. The tit on the side panels are made to pass thru the tank grommet and lock on the opposite side. Oh well I knew the risk going into this and like someone else mentioned clarke's white is not TW white it's much duller and darker. Now to go dry out, bubble wrap my stock tank and hide it so it stays pristine. (EDIT 2018) The tank is now a dirty tan color from the gasoline staining the tank.



Might try something like this to hold the sideplates on if I can find the right size.
 

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EEek!



Pgilles has a point and I am in agreeance. The first tank I bought did not fit well at all. I was stupid and ended up drilling the hole "bigger". I found out the hard way NOT to do this, as the hole where our side cover tabs fit into, are hollow!!! It leaked after I was able to fit it on.



I did send an email with a small complaint within. I was very lucky to have a new one sent to me for a discount, after returning the defected one that was then ruined completely (by me)



The 2nd tank fit better but the right side is still reluctant to fit properly :/



I have an 06'

-Adam
 

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I sent an e-mail to one of the supplier links re this discussion about Clarke tanks. I read with some concern about the - apparently - many problems with fit. I got this response yesterday:



Hmmmm, I read a few posts and have to say many different variables come into play with a plastic fuel tank new or used. Then you start considering the variables of placing a new plastic fuel tank on a used bike that has many different metal and plastic parts that can expand and contract over time, get bent and damaged when the bike falls over or gets in a battle with rocks and trees, etc. Then you add in different levels of personal knowledge, technical experience (or lack of) and soon you can't make any educated decisions without a full-blown scientific study backed by statistics. I remember trying to fit a Clarke tank on my CR500 some time back and couldn't get it to fit properly. I contacted the factory and they said to simply blow some compressed air into it so it would expand the lobes enough to get it on the bike properly. It worked great! After a few weeks on the bike with gas in it it expanded and self adjusted to the bike...it then fit like a glove every time I removed and re-installed. I have a lot of other personal stories and customer stories but I imagine you get the point by now. I looked through our sales and we have sold 9 of these tanks since we started selling them in October and none of our customers contacted us with complaints or concerns. Knowing that you have done some up-front research and that you already have reservations, I am assuming you will be very critical of the fuel tank and installation. I am still willing to bet that we will have sold 10 of these fuel tanks without any issues. Of course if that is not the case, we'll be more than happy to take the tank back and waive the 20% re-stocking fee as long as it is a common color and is in original new condition (no gas). I am confident you will find this tank a great value for a off-road, race-quality plastic fuel tank. If not, at least you have the choice of a brand new steel fuel tank manufactured under strict tolerances. We look forward to serving you! Cheers,
 

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Same old problem still exists, but with a little finagling it will fit.
So is this still a problem 6 years later, or did they get it sorted out?
 

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I have had my tank since 2010. No leaks anywhere. I noticed a blemish, but thought it was caused by the previous owner as it was purchased with 396 miles on it. I have 16340 miles now on that TW.

My only problem is sometimes the cap lid is hard to screw down, I think it looks like it just needs to be cleaned, but I’d rather ride than mess with cleaning it.
 

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I’m looking at upgrading my fuel tank on my 2002 TW. It mostly white with a blue frame and trim. Getting the extra gallon is the sole reason. I have a spare petcock so that problem is solved. Who would be the recommended dealer to purchase it through? Here’s a chance to give a plug to the dealers that deserve it.
Priorities would be price and the ability to return it without fees if I happen to get a poor specimen. After reading about the white ones turning brown I think I’ll go blue. Are the plastic caps they come with adequate, or is the metal one worth the price they’re asking? Are they still having problems with the right side cover not matching up?
Thanks for any advise.
 

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I bought mine from Just Gas Tanks, they replaced the first "defective" one where the petcock wouldn't seal, told me to file the plastic flat.... I expect I'll be buying a metal cap at some poing, might as well but it now and get it over with. JGT did give me a discount for mentioning the group buy thread from here years ago, it's worth the phone call.
 

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it's funny if ever there was a mold worth remaking properly it's the TW200 perhaps the longest factory production run in history and an ever growing cult following Clarke could have sold a lot more tanks if they made a perfect product including smoothing the petcock surface area before selling the tanks. It's still not too late and they could even advertise as "new and improved Gen 2" etc

I doubt they will ever correct the issues so I always steer people to the XT225 or XT350 steel tank conversion
 
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