Mercedes Mullins
Flash rust is a common issue for motorcycle fuel tanks, and it can cause significant problems for your bike's fuel tank, fuel filter, carb, and engine. This guide will take you through the steps to prevent flash rust in your motorcycle fuel tank, as well as how to deal with it if it occurs.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Flashing a motorcycle fuel tank | Preventing flash rust |
| Keep the tank dry | |
| Use protective coatings | |
| Store the motorcycle in a dry place | |
| Keep the tank full | |
| Use a fuel stabilizer | |
| Regularly check and maintain the tank | |
| Clean and dry the tank thoroughly | |
| Use rust inhibitors to protect the metal | |
| Regularly inspect the tank for signs of rust | |
| Use a flashlight to see inside the tank | |
| Use a hairdryer or heat gun to speed up drying | |
| Use compressed air to blow air into the tank | |
| Use a gas tank sealer to prevent rusting | |
| Use kerosene or motor oil to prevent rust |
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What You'll Learn
Use a flashlight to inspect the tank
To flash a motorcycle fuel tank, you will need to inspect the tank for rust and damage. This is best done by removing the tank and draining the fuel. Once the tank is empty, use a flashlight to peer inside and check for signs of rust or debris. Shine the light around the interior, looking for discolouration, pitting, pinholes, or missing metal. If the tank is rusty, you will need to decide whether to replace it or attempt to treat it. If the rusting is mild, you may be able to clean and de-rust the tank. However, if there is heavy rust or damage, you may need to cut the tank open for further inspection and repair.
A flashlight is an essential tool for inspecting a motorcycle fuel tank. It allows you to see inside the dark interior of the tank and identify any issues. When shining the flashlight into the tank, look for any signs of rust or corrosion. Rust particles or debris in the fuel indicate severe rusting or corrosion. If the tank is severely rusted, you may need to replace it.
If the tank is made of metal, check for any pitting, pinholes, or missing sections. These issues can be caused by metal fabrication and body work. If the structural integrity of the tank is compromised, you may need to cut it open for further inspection and repair. In some cases, you may need to seek professional help or replace the tank entirely.
When inspecting the tank, also check the seals and replace them if necessary. Look for any cracks or small holes in the tank and seal them with rubber or vinyl vacuum caps. Ensure that the tank is thoroughly cleaned and dried before refilling it with gas. Proper gas tank care and maintenance can help prevent the formation of new rust.
To check the fuel level in your motorcycle tank, you can also use a flashlight. By shining the light into the tank, you can estimate the percentage of the tank that is full. For example, if you have a 5-gallon tank and it appears to be half full, you know you have approximately 2.5 gallons of fuel remaining. This method can be more accurate than calculating MPG and tracking mileage.
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Remove the tank and drain fuel
Removing the fuel from your motorcycle's tank is a necessary step for many repairs. It is not a difficult task, but it is time-consuming and requires patience. Before you begin, make sure your motorcycle is in a stable and secure position. This could mean placing it on a kickstand, a lift, or wheel stands.
To remove the fuel, you have a few options. You can run the engine until the tank is empty, or you can siphon the fuel out. If you choose to siphon, be sure to use a hose and container to catch the fuel. You can also use a rag to stuff into the upper opening around the hose to prevent spills. Another option is to use a second hose to blow air into the tank and force the fuel out. Modern bikes with quick fasteners on the fuel line to the fuel pump are more reliable but may still dribble fuel.
If your bike has a fuel petcock, turning it to the OFF position will prevent fuel from flowing out when you remove the tank. If there is no OFF position, leaving it on is fine unless it is defective. It is usually easier to remove the fuel line from the petcock than from the carb. There may also be a second line to the petcock if it is vacuum-operated.
To relieve the pressure in the fuel lines, you will need to unplug the connector for your fuel pump. This may be located under the seat, under the tank, or on the sides. Once the fuel pump is unplugged, turn the motorcycle on and hold the start button for a few seconds. This will run the remaining fuel in the system through to the engine without adding new fuel. Finally, remove the key and reconnect the fuel pump.
Now that the fuel is drained, you can proceed to remove the tank. This will typically involve removing any tank straps, tank bolts, and disconnecting the fuel pump and gas lines. Be sure to have your service manual ready, as the steps may vary slightly depending on your motorcycle's make and model.
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Clean the tank with vinegar and water
To clean a motorcycle fuel tank with vinegar and water, you should use white vinegar due to its mild acidity, which is strong enough to remove rust without damaging your bike or posing health risks. Before you begin, ensure you are working outdoors or in a well-ventilated area.
First, fill the tank with vinegar and leave it to soak for 24 hours. After this, you need to neutralise the vinegar with baking soda. It is unclear whether you should pour the baking soda directly into the vinegar or rinse the tank first. However, you should ensure that you flush the tank with plenty of water after neutralising the vinegar.
You can also add salt to the vinegar to speed up the process, although this may not be necessary for a fuel tank. It is important to note that vinegar can damage rubber, so be cautious if there are any rubber fuel lines or fittings in the tank.
After cleaning, you can prevent flash rust by using a fuel-soluble sealer, kerosene, motor oil, or two-stroke oil. If you are going to reinstall the tank immediately, you can use kerosene to coat the tank's innards and prevent flash rust. If the tank is going to sit on a shelf for a while, a thicker option like motor oil or two-stroke oil is recommended. You can also use a gas tank sealer or high-octane gas and a fuel stabilizer to prevent flash rust.
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Dry the tank with a hairdryer
Drying your motorcycle fuel tank is crucial to maintaining your bike. Flash rust can quickly damage your motorcycle's gas tank, so it's important to work quickly and efficiently.
After cleaning your tank, use a hairdryer to dry it thoroughly. Be careful not to use a high heat setting, as this can damage the paint. Keep the dryer moving around the tank, ensuring all areas are reached, and use your fingers to feel the tank to make sure it's not getting too hot. You can also use compressed air to blow into the tank and remove any remaining water droplets.
If you're using a hairdryer, it's important to work quickly, especially if the moisture content in the air is high, as flash rust can form within minutes of metal being exposed to air and moisture. This thin layer of rust is usually fine and will be caught by a fuel filter, but it's best to avoid it altogether if possible.
To prevent flash rust, you can also coat the inside of the tank with a fuel-soluble sealer or a fuel stabilizer. Kerosene or motor oil can also be used to coat the tank's innards and prevent flash rust.
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Apply a fuel-soluble sealer
Applying a fuel-soluble sealer to your motorcycle fuel tank is a great way to prevent flash rust and protect your tank from the ethanol in modern fuel. Here is a step-by-step guide to applying a fuel-soluble sealer:
Prepare the Tank
Before applying any sealer, it is important to prepare your tank. This includes removing any badges, filler caps, fuel taps, and kneepads that are screwed on. If you plan to use bolts to seal the tap holes, wrap them with Teflon tape. For a tighter seal, use rubber plugs and push them in firmly. These steps will help prevent any sealer from leaking out.
Clean the Tank
While some sealers claim that you don't need to remove rust first, it is always better to start with a clean, rust-free surface. Use a rust remover like Evapo-Rust to clean the inside of your tank. Fill the tank with the rust remover and let it sit for several hours. Then, drain the solution and blow-dry the tank with compressed air.
Choose the Right Sealer
Not all sealers are created equal. Choose a sealer that is fuel-soluble and will stand up to the ethanol in modern fuel, such as a Novolac epoxy sealer. Rustbuster's Slosh Fuel Tank Sealer is another excellent option, as it has been tested with high concentrations of corn ethanol without degradation.
Apply the Sealer
With your chosen sealer, follow the instructions for mixing if necessary. Pour the sealer into the tank and quickly seal the filler neck opening. Rotate the tank to ensure all interior surfaces are evenly coated. You may need to roll the tank around and give it time to settle in different orientations. After about 15 minutes, the interior should have a good, even coating.
Cure Time
Once you have achieved a satisfactory coating, set the tank down and remove the filler neck plug. Leave the tank undisturbed for 48 hours to allow the sealer to cure completely.
Reinstall the Tank
After the curing process is complete, you can reinstall the fuel taps and any other hardware that was previously removed. Your tank is now sealed and protected from flash rust and the harmful effects of modern fuel.
Remember, always work in a well-ventilated area and wear appropriate protective gear when handling chemicals.
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Frequently asked questions
Flash rust occurs when a motorcycle fuel tank is exposed to moisture and air, causing the inside of the tank to rust and deteriorate. This can impact the performance of the bike.
To prevent flash rust, you need to keep the tank dry and use protective coatings. Regularly clean the tank and use a rust inhibitor spray to add a protective layer. Keep the tank filled with high-octane gas and use a fuel stabilizer.
There are several ways to clean flash rust from a motorcycle fuel tank. One method is to use a vinegar soak, followed by a water and baking soda solution to neutralise the vinegar. Another method is to use a tank sealer or a fuel-soluble sealer. You can also use a heat gun or hair dryer to dry the tank, but be careful not to damage the paint.
