Mercedes Mullins
Plastic motorcycle fuel tanks can expand due to the use of ethanol-based fuel, which causes water to pool at the bottom of the tank, leading to absorption by the nylon material. To shrink an expanded plastic fuel tank, some recommend using a vacuum pump and heat gun with a tight seal, while others suggest heating from the inside out with a torch. Removing and drying the tank in a low-humidity environment for several weeks is another potential solution, although results may vary. To prevent future expansion, treatments such as Caswell coating or additives like Eastwood's Fuel Guard can be applied, and the use of ethanol-free gas is advised.
| Characteristics | Values |
|---|---|
| Fuel type | Non-oxygenated, ethanol-free gas |
| Additives | Fuel Guard Additive, Caswell Coating, Flowliner Armour Coat Tank Sealer |
| Heat | May cause ethanol to break down and separate into water |
| Vacuum | Use a vacuum pump and heat gun with a tight seal |
| Time | May take days or weeks to see shrinkage |
| Environment | Low humidity, dessicants, moving air |
| Alternatives | Use a torch, turn the tank inside out, use heat shrink tubing |
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What You'll Learn
Remove the tank and dry it out
Removing the tank and drying it out is a crucial step in shrinking a plastic motorcycle fuel tank. This process can help address issues caused by fuel expansion and moisture absorption. Here's a detailed guide on how to remove the tank and dry it out effectively:
Before removing the tank, it is important to drain the fuel. Seal all holes in the tank, including the filler cap and petcock outlet. If your tank has crossover tubes or large openings, use appropriate sealing methods such as silicone plugs, rubber or vinyl vacuum caps, or gasket block-off plates.
Once the tank is sealed, you can proceed to remove it from the motorcycle, following the specific instructions for your motorcycle model. After removing the tank, it is crucial to ensure it is completely empty. Turn the tank upside down and use a cloth or rag to absorb any remaining fuel or fluid. You can also use a manual drain pump or a siphon pump to remove liquids from the tank.
The next step is to dry out the tank. This can be done by using a heat gun or a hair dryer on a low setting. Be cautious when using a heat gun as it can damage the paint if it gets too hot. Keep the heat source moving and regularly check the tank's temperature with your fingers to prevent overheating. An alternative method is to use compressed air or a compressor hose to blow air into the tank, displacing any remaining vapours and helping to evaporate any residual fuel. Ensure you are in a well-ventilated area to avoid inhaling fumes.
Drying the tank in a low-humidity environment is recommended. You can also use dessicants or moving air to aid in the drying process. It may take several weeks for the tank to completely dry and shrink, so patience is key.
Finally, to prevent rust from forming during and after the drying process, it is important to work quickly. Full tanks displace air, which is necessary for rust formation. If you plan on leaving the tank empty for an extended period, consider coating the inside with WD-40 or a similar lubricant. Alternatively, you can fill the tank with fuel promptly to prevent rust.
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Use a vacuum pump
Using a vacuum pump is an effective way to shrink a plastic motorcycle fuel tank. This method involves creating a vacuum inside the tank, which will help to reduce the volume and shrink the tank. Here is a step-by-step guide on how to use a vacuum pump for this purpose:
Firstly, ensure that the fuel tank is removed from the motorcycle and that it is completely empty. It is crucial to confirm that the tank is free of any fuel or flammable substances before proceeding. Allow the tank to be off the bike for a day or two, or wash it out with a degreaser, to ensure that any remaining fuel residue is eliminated.
Once the tank is prepared, connect the vacuum pump to the fuel tank using appropriate fittings and hoses. Ensure that the connections are secure and tight to maintain an airtight seal. Create a vacuum inside the tank by activating the vacuum pump. It is important to monitor the vacuum level and ensure that it is strong enough to induce shrinkage in the plastic tank.
While maintaining the vacuum, use a heat gun to apply heat to the sides of the tank. This combination of heat and vacuum will help promote shrinkage. Be cautious when handling the heat gun and ensure that the heat is distributed evenly to avoid warping or damaging the plastic. Apply heat until the tank reaches the desired size, but avoid overheating to prevent any potential melting or deformation.
After achieving the desired shrinkage, release the vacuum slowly and carefully. It is important to allow the tank to cool down gradually to room temperature before handling extensively or reinstalling it onto the motorcycle. Ensure that all seals and connections are secure before refilling the fuel tank and testing the motorcycle.
By following these steps and using a vacuum pump, you can effectively shrink a plastic motorcycle fuel tank. This method allows for controlled shrinkage and helps to restore the tank to its original size, ensuring a proper fit on your motorcycle. Remember to take the necessary safety precautions when working with fuel tanks and heat guns to avoid any accidents or damage.
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Use a heat gun
Using a heat gun is a common method for reshaping a motorcycle fuel tank. It is important to exercise caution when using a heat gun to avoid making the plastic brittle and more prone to fracture.
Firstly, remove the tank from the motorcycle and drain all the gas from it. Next, use the heat gun to carefully heat up the plastic, being mindful not to overheat any one area, which could cause damage. Use a piece of metal or a similar tool to gently bend and press the tank into the desired shape. It is recommended to work slowly and adjust the tank a little at a time. After each adjustment, try fitting the tank back onto the motorcycle to check the clearance.
It is also suggested to have a helper pour ice water onto the reshaped areas of the tank to aid in setting the new shape. This process can be repeated as needed until the desired shape is achieved and the tank fits properly.
When using a heat gun, it is crucial to prioritize safety. Wear appropriate protective gear, such as heat-resistant gloves and eye protection, to shield yourself from potential harm. Additionally, ensure that the work area is well-ventilated to prevent the buildup of fumes. By taking these precautions, you can effectively utilize a heat gun to shrink and reshape your motorcycle fuel tank.
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Use ethanol-free gas
One of the most common reasons for a motorcycle's fuel tank to expand is the use of ethanol-based fuel. Ethanol has a negative impact on the plastic used in fuel tanks, causing them to swell and deform over time. This can lead to reduced clearance between the tank and other components, making it difficult to remove and install the tank.
To prevent this issue and maintain the integrity of your motorcycle's fuel tank, it is recommended to use ethanol-free gas. Here are several reasons why:
Engine Performance and Mileage:
Ethanol has a lower energy density compared to gasoline, resulting in reduced mileage and engine performance. Studies have shown that a pound of ethanol produces 30% fewer BTUs of heat than a pound of gasoline, leading to a decrease in mileage proportional to the percentage of ethanol in the fuel.
Corrosion and Damage to Fuel System:
Ethanol-based fuel can cause corrosion and damage to metal, rubber, and plastic components in the fuel system. The presence of ethanol can lead to the formation of water droplets at the bottom of the tank, which can then be absorbed by the nylon material commonly used in fuel tanks. This absorption of water can result in swelling and deformation of the tank. Additionally, exposure to alcohol can rust metal fuel-system parts and damage rubber and plastic sealing materials.
Increased Maintenance and Costs:
The use of ethanol-blended fuel can lead to higher maintenance expenses. Issues such as corrosion, damaged seals, and reduced engine performance will require more frequent repairs and part replacements. The cost of ethanol-free fuel is typically higher, but the reduced maintenance and repair costs associated with ethanol-based fuel can offset this difference.
Manufacturer Recommendations:
Many motorcycle manufacturers, including Ducati, Harley-Davidson, and Suzuki, recommend using pure gasoline or ethanol-free fuel in their motorcycles. Ducati specifically considers ethanol to be a gas additive, and its use may void the cycle's warranty. By following the manufacturer's recommendations, you can ensure optimal performance and maintain the validity of your warranty.
Switching to ethanol-free gas can help prevent the expansion of your motorcycle's fuel tank and reduce the likelihood of the issues mentioned above. It is important to read fuel labels carefully and choose ethanol-free options whenever possible to maintain the longevity and performance of your motorcycle.
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Apply Caswell coating
To apply the Caswell coating to a motorcycle fuel tank, follow these steps:
Firstly, drain your fuel tank and let it sit for a minimum of two days to ensure it is completely dry. This is crucial as any remaining fuel, oil, or grease can affect the coating process. You can speed up the drying process by laying the tank on its side and using a fan to blow air through the holes. During this time, you can also prepare the coating by keeping it next to the tank, ensuring it reaches the same temperature of 70-90 degrees Fahrenheit.
Once the tank is dry, you need to clean the inside thoroughly. Use drywall screws, soap, and water to remove any residue or contaminants. Make sure the tank is free of any grease, fuel, oil, or any other substances. After cleaning, inspect the tank for any tape that may have become wet during the process and re-apply it. Additionally, check any sealed surfaces and close any open vent lines with tape.
Now, you are ready to apply the Caswell coating. Before opening the coating container, determine how you will set the tank at a suitable angle to allow the epoxy to seep out on its own. You can use a stir stick and a container, such as a margarine tub or a cake tray, to catch any excess epoxy. Follow the mixing instructions provided with the Caswell coating kit, as improper mixing can lead to failure.
After mixing, apply the Caswell coating evenly to the inside of the tank. Ensure you have adequate coverage and pay attention to the manufacturer's instructions for the required drying time. The Caswell coating will typically need to sit for at least 24 hours in a temperature-controlled room before you can refuel the tank.
The Caswell coating is known for its durability and effectiveness in sealing motorcycle fuel tanks. It is a popular choice for preventing ethanol-related issues and has been used successfully on various motorcycles, including Ducati and Yamaha models.
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Frequently asked questions
There are several methods to shrink a plastic motorcycle fuel tank. One method is to use a vacuum pump hooked to your vent hose, creating a tight seal, and then using a heat gun on the sides of the tank. Another method is to dry the tank in a low-humidity environment for several weeks, allowing it to shrink.
To prevent fuel tank expansion, you can use ethanol-free gas or high-octane fuel. Additionally, you can coat the inside of the tank with treatments such as Caswell coating or Flowliner Armour coat tank sealer.
One sign that your plastic motorcycle fuel tank may need shrinking is if it has expanded, causing a tight squeeze when removing or inserting it into the frame. Another sign is bubbling on the surface of the tank, indicating ethanol attack.
