How to Restore Motorcycle Gas Tanks

Age and high use can leave the inside of your motorcycle gas tank coated in rust and varnish that can break free and clog your fuel delivery lines. You don't need to replace the tank, but you can restore it fairly easily. The process is time-consuming, but simple. And it can be done with both metal or plastic (desert) tanks.

Things You'll Need

  • Dry ice
  • Paint stripper
  • Paint scraper
  • Rust converter if needed)
  • Automotive paint
  • Automotive sealer
  • Varnish/rust remover (liquid)
  • Hair dryer
  • Gas tank sealer
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Instructions

    • 1

      Turn the fuel feed petcock to the off position and disconnect the fuel line from the petcock.

    • 2

      Remove the gas tank from the motorcycle; consult your owner's manual for the specific way to do this for your make and model. Usually, gas tanks are held on by pressure only and any additional fairings surrounding it.

    • 3

      Empty the gas into a glass or metal container. Push one small piece of dry ice into the tank; the mist from the dry ice will force ouot any remaining fumes.

    • 4

      Apply your paint remover to the outside of the tank, following the instructions as written on the product you choose. Any automotive or airplane stripper will work. However, if you have a plastic tank (a desert tank,) skip this step.

    • 5

      Remove the old paint with a paint scraper. Examine the outside of the tank for any beginning signs of rust or holes. Treat any that you find with rust converter and repaint the tank. Let the tank dry completely (this will depend on the product you use and the climate you are in) before continuing on to the next step.

    • 6

      Pour enough liquid varnish/rust remover into the tank to completely cover the bottom. About 1/2 inch of depth is good enough. Cap the tank and shake it well, then set the tank aside. Repeat this every 15 minutes for one hour. Repeating this is an important part of the process to remove rust from the gas tank -- go longer if need be, but not shorter in time or repetitions. Pour out the varnish/rust remover.

    • 7

      Rinse the tank with warm running water until the water coming out of the tank is clear. Dry the inside of the tank with a hair dryer set on low. Simply turn the tank upside down and aim the hair dryer into it and let it run for about 15 minutes. Set the tank aside, with no cap, and let it continue air drying for another 20 minutes.

    • 8

      Apply the gas tank sealer to the interior of your motorcycle gas tank following the directions. The process will be similar regardless of whether you have a plastic or metal tank.