Katerina Swanson
Rust in a motorcycle fuel tank can be a headache, but it doesn't have to be a death sentence. Before you begin the removal process, it's important to assess the severity of the corrosion and the condition of the tank. If the rust has caused structural issues, it may be more cost-effective to replace the tank entirely. However, if the tank is still salvageable, there are a few methods you can use to remove the rust. These methods can be broadly categorised into chemical abatement, manual abatement, or a mixture of both. Chemical abatement involves using mild acids like white vinegar or stronger options like phosphoric acid or muriatic acid to eat into the rust and remove it. Manual abatement, on the other hand, uses abrasive materials like gravel, nuts, and bolts to scrub away the rust. It's important to work in a well-ventilated area when dealing with strong chemicals and to always follow safe acid disposal practices. Additionally, proper maintenance and storage of your motorcycle can help prevent rust issues in the future.
Characteristics and Values Table for Cleaning Rust out of a Motorcycle Fuel Tank
| Characteristics | Values |
|---|---|
| First Step | Inspect the tank to determine the severity of the corrosion. Check the exterior for damage such as deep dents, large cracks, or severe impacts. |
| Chemical Treatment | Mild acids like white vinegar, stronger acids like phosphoric acid or muriatic acid, or off-the-shelf rust cleaners can be used. |
| Manual Treatment | Abrasive materials such as gravel, nuts and bolts, or BBs can be used to scrub the tank. |
| Combined Treatment | A combination of chemical and manual treatments can be used. |
| Sealing | Seal all holes in the tank using silicone plugs, rubber or vinyl vacuum caps, or fuel-soluble sealers. |
| Cleaning Solution | Drain the cleaning solution and rinse with a baking soda solution to neutralize acid residue. Then, rinse with clean water and drain again. |
| Fuel Filter | Install an inline fuel filter to catch any remaining rust particles. |
| Prevention | Ride the motorcycle often and store it in a safe environment to prevent condensation and rust formation. |
| Kit | A Kreem kit or Evapo-Rust can be purchased to remove rust and seal the tank. |
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What You'll Learn
Assess the tank's condition and consider replacement
Before attempting to clean the rust out of your motorcycle fuel tank, it is important to assess the condition of the tank and consider whether it may be more prudent to simply replace it. Not all tanks can be cleaned and brought back to good condition, and sometimes, it is better to replace the tank than to try to de-rust it.
The first step is to uninstall the tank from the motorcycle and conduct a complete visual inspection. Check the exterior for damage, such as deep dents, large cracks, or severe impacts. If the rust has led to or exacerbated any structural issues, the tank may need to be replaced.
The next step is to determine the severity of the corrosion. Before removing the rust, push on the rusted spots to see if they give way and create a hole. If the tank is too damaged, de-rusting alone may not be sufficient to fix it. Additionally, consider the rarity and desirability of the tank. If the motorcycle is a classic or rare make and model, finding spare parts can be difficult and expensive. On the other hand, if the motorcycle is newer or still available in dealerships, spare or aftermarket parts may be more readily available.
Finally, consider the cost-effectiveness of your options. Deciding whether to buy a replacement tank or spend time and money on de-rusting and repairing the existing one can come down to a financial decision. Weigh the costs of replacement against the costs of rust removal and treatment, and choose the option that makes the most financial sense for your situation.
By carefully assessing the condition of your motorcycle fuel tank and considering the factors mentioned above, you can make an informed decision about whether to attempt rust removal or opt for a replacement tank.
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Seal the holes in the tank
Sealing the holes in the tank is an important step in cleaning rust out of a motorcycle fuel tank. This is because chemical fumes can be harmful, so it is recommended to work in a ventilated area.
Most tanks will have a filler cap and a petcock outlet, but others may have crossover tubes, like dual-tank Harleys and dirt bikes with two big lobes that overhang the engine. It is important to have the right equipment to do the job correctly. Plugs, stoppers, vacuum caps, and threaded fittings can be used to seal the holes. Silicone plugs and rubber or vinyl vacuum caps are good options for small holes and bungs. If you are working on a modern motorcycle, you may need to remove the fuel pump plate.
If you are going to reinstall the tank immediately, a fuel-soluble sealer can be used. Toss a little kerosene in the tank, seal it back up, and swish it around, coating the tank's innards completely. This will prevent the formation of flash rust. If the tank is likely to sit for a while, something thicker, like motor oil or two-stroke oil, can be used.
There are also commercial kits available, such as the Kreem Complete Petrol/Gas Fuel Sealer Kit, which includes prep solutions and sealant. Another option is to use a fuel tank liner product, such as Red-Kote, which creates a coating inside the tank to seal it.
It is important to note that not all tanks can be cleaned and restored to good condition, so it is essential to assess the condition of the tank and decide if replacement is a better option.
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Use a chemical abatement, like vinegar or acid
Using a chemical abatement like vinegar or acid is a common method for cleaning rust out of a motorcycle fuel tank. Before attempting this, it is important to inspect the tank to determine the severity of the corrosion. Light rusting on the surface is relatively harmless and does not generally signal damage to the interior. However, if the rust has spread under the paint, causing it to flake or peel off, the tank's metal may have weakened.
If you decide to proceed with a chemical treatment, the first step is to remove the tank and empty it of fuel. If there are any cracks or small holes, seal them using rubber or vinyl vacuum caps. It is also important to perform this process in a well-ventilated area or outdoors, as most cleaning and de-rusting agents produce strong odours that can cause nausea or headaches.
The safest acid to use at home is white vinegar (acetic acid). It is inexpensive, non-toxic, widely available, and the least likely to damage the tank's underlying metal. Before using vinegar or any other acid, it is recommended to place a few test pieces in a glass or ceramic bowl to ensure the acid does not have an adverse reaction. While vinegar is safer, it is also not as fast-acting as other acids and may take several hours or even overnight to finish.
If you decide to use a stronger acid, such as phosphoric acid or muriatic acid, it is important to follow safe acid disposal practices. These acids should be diluted with water before use and require appropriate protective equipment due to their stronger fumes. They can also damage the metal if left inside the tank for too long.
To use vinegar or acid to clean the fuel tank, pour in the cleaning solution until roughly half of the tank is full. Then, drop in a few agitators, such as steel BBs or small nuts and bolts, which will help dislodge any particles of rust. Shake the tank gently to make the cleaning solution reach all interior surfaces. Finally, let the solution sit and soak.
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Neutralise acid with baking soda and rinse
To neutralise acid with baking soda and rinse, follow these steps:
Firstly, drain the cleaning solution from the tank. Turn the tank upside down and shake it to retrieve any agitators. Next, rinse the tank with a baking soda solution. This will neutralise any remaining acid residue and prevent damage to the metal inside. Drain the tank of the baking soda solution. Then, rinse the tank with clean water and drain it again.
After neutralising the acid, inspect the seals and replace them if necessary. Now, the gas tank is ready to be reinstalled and refilled with gas. To prevent future rust, ensure the motorcycle is stored in a safe environment and ride it often to prevent condensation inside the gas tank.
It is important to note that before attempting to clean the rust, you should thoroughly inspect the tank to determine the severity of the corrosion. If the rust has caused structural issues, the tank may need to be replaced. Additionally, always prioritise safety when working with strong chemicals and acids.
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Reinstall and refill the tank
Once you are satisfied that the tank is clean and free of rust, it's time to reinstall and refill it. First, inspect the seals and replace them if necessary. If you are going to reinstall the tank immediately, toss a little kerosene in there, seal it back up, and swish it around, coating the tank’s innards completely. That will prevent the formation of flash rust. If you are building a bike and the tank is likely to sit on the shelf for a while, use something a touch thicker, like motor oil or two-stroke oil.
Afterwards, you can reinstall the tank. It is recommended to install an inline fuel filter between the tank and the fuel pump. The filter will catch any rust particles that may have been left behind. If you are using a vintage bike, you may also need to pull out your fuel pump plate.
Finally, refill the tank with gas. To prevent future rust, it is recommended to ride often and keep the motorcycle stored in a safe environment to prevent condensation inside the gas tank. Additionally, consider using ethanol-free gas, as ethanol gas attracts water out of the atmosphere.
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Frequently asked questions
First, determine the severity of the corrosion by inspecting the tank for damage, such as deep dents, large cracks, or severe impacts. If the rust has caused structural issues, the tank may need to be replaced. If the tank can be salvaged, drain the fuel, seal the holes, and fill the tank with a rust treatment, such as white vinegar, a caustic soda solution, or Evapo-Rust. Let it sit, then empty the tank and rinse it with a baking soda solution to neutralise any remaining acid.
There are several products you can use to clean rust out of a motorcycle fuel tank. These include:
- White vinegar
- Caustic soda solution
- Evapo-Rust
- Kerosene
- Sea Foam
- Kreem kit
- Muriatic acid
- Phosphoric acid
The best way to clean rust out of a motorcycle fuel tank will depend on the severity of the corrosion and the products you have access to. If the tank is only lightly corroded, you may be able to get away with using a mild acid, such as white vinegar. If the tank is more heavily corroded, you may need to use a stronger acid, such as muriatic acid, or a combination of chemical and manual abatement.
To prevent rust from forming in your motorcycle fuel tank, try to ride your bike often and store it in a safe, dry environment. This will help to prevent condensation from building up inside the tank, which can lead to rust formation.
