A motorcycle fuel tank is a container where the gasoline is stored and from where it is sent into the engine. There are different types of fuel tanks, and they range in different sizes and shapes depending on the motorcycle they are being installed. It is essential to know how to maintain and repair your fuel tank, and that is why we are going to guide you in the step-by-step process of repairing the fuel tank.
So how do you repair a motorcycle fuel tank? Drain the fuel tank and remove it from the motorcycle. The two best ways to repair the tank are using epoxy or soldering to fill holes. It all depends on how difficult your situation is. Once you have repaired holes, check if it still leaks. Return the tank on the motorcycle if it doesn’t leak.
This article will also teach you other helpful tips like cleaning a motorcycle fuel tank and many other tips, so stay with us if you want to learn something new.
Table of Contents
How to Fix a Motorcycle Fuel Tank?
A motorcycle fuel tank is made of thin metal, and because of that, it is not unusual for it to get pierced, especially if you fall during a ride. Manufacturing imperfections can also be responsible for the tank’s weak spots, although it is rarely the case. You must take off the tank and repair it if you notice any sign of leaking. There is a possibility that the tank catches fire because the gasoline is highly flammable, resulting in you having injuries.
Buying a new fuel tank can cost a lot, the price can vary from 1300-2000$ or even more, which depends on your motorcycle type ( some vintage models have expensive parts), and that is why we want to help you with this article to fix it by yourself and to fix it as cheaply as possible.
Step 1: Empty the Fuel Tank
Before starting any work, you need to empty the fuel tank. Use an empty fuel container to drain the fuel in, and the first thing you need to do is detach the fuel line. Use a pair of pliers to squeeze the retaining clamp, and as soon as you press the clamp, you can separate the fuel line from the fuel tank nipple. Put some nylon under the motorcycle and tank to prevent gas spilling, and in case that the gas gets spilled somehow, use a rag to clean any spilled gasoline.
Step 2: Take off the Fuel Tank
To remove the tank, you need to unloosen the screw placed in the center of the fuel tank. There is a possibility that you will have to remove the seat to reach this screw. Use a socket wrench to unscrew it. You can take off the tank after you remove the screw. Shake a tank a little bit to easily remove it from the motorcycle.
Step 3: Repair the Tank
Take off the fuel tank cap and let the air out. You can use a compressor to make this process faster, take an air hose and put it in the tank, and turn on the air compressor. This should last for around 10-15 minutes. If you see any signs of rust, you need to clean it. Take acetone and pour up to two quarts of it in the fuel tank along with the small screws and nuts.
Secure the fill hole with plastic wrap around it and use a rubber band to press the wrap against the edge of the hole. Rotate and shake the tank to make sure that the nuts and screws get in contact with every part of the tank. The reason you put them in the tank is to knock out and remove away all the rust from the tank and will also make scratches that will enable the epoxy to stick better to the fuel tank’s surface. Once you have shaken the tank enough and cleaned the rust, drain it and dry it the same way as you did earlier.
Step 4: Seal the Tank
Take the epoxy and mix it following the directions written on its package. Once you have mixed the epoxy, pour it into the fuel tank. Take a piece of plastic wrap, put it over the fill hole, and secure it with a rubber band. Smear the epoxy and empty the fuel tank. Let the epoxy harden for at least one day before you replace and fill the fuel tank. If you notice that the tank still leaks on some spots, you need to repeat the process but this time, do it with more attention.
Step 5: Return the Fuel Tank
Once you see that the fuel tank is good to go and that there aren’t any leaking spots, you are good to go, and you can install the tank on the motorcycle.
How to Solder Motorcycle Fuel Tank Holes?
After I had done little research, I decided I was going to fill the holes but fill them with solder. If you have never done that before, don’t worry because it is very easy to be done as long as you follow our instructions, you shouldn’t have any problem. Soldering is another very beneficial and proper way to fix and fill the holes on your fuel tank, especially if the holes are too large to be filled by any tank liner.
Tip: Try to get a good powerful soldering iron as it will significantly help you to do this process the way it needs to be done.
So let’s get started:
Step 1: Get a Soldering Iron, Flux, and Solder
Flux 
Solder 
Soldering Iron
The first thing you need to do is get a strong soldering iron, some kind of flux I prefer the liquid type, and some solder.
Step 2: Clean the Area
Clean the area that you need to solder by sanding up with some sandpaper and then cleaning it up with some acetone before you start working on it.
Step 3: Apply the Flux
Once you clean the surface, apply the flux to the work area.
Step 4: Apply the Solder
Once the iron gets to 800 degrees, start to apply the solder.
CAUTION: Your fuel tank must be clean and make sure that there is no debris on the inside, and MOST IMPORTANTLY any kind of LIQUID VAPORS OR GASES, because you will be applying a lot of heat on the fuel tank. Don’t rush and ensure that everything is safe and secure. You don’t want the fuel tank to blow up in your face or harm you and your surroundings in any other way.
Step 5: Sand the Fuel Tank
After you complete the soldering process, you need to smooth the surface, and to do that; you will need to use sandpaper once again.
Step 6: Return the Fuel Tank
Once the fuel tank is all fixed, and the holes are filled, one last step you need to do is to return the fuel tank on the motorcycle.
Here is a nice video that explains How to Solder Holes in Motorcycle Fuel Tanks:
Why Does a Motorcycle Fuel Tank Leak?
We would like to know what is the reason for leaking as soon as we notice that there are some leaking signs on our fuel tank. It can be very annoying to see that there is a problem, but we don’t know what it is. Don’t worry because we will explain to you the most common issue related to fuel leaking, and that is fuel tank holes.
Fuel Tank Holes
Fuel tank holes are the most common reason responsible for fuel tank leaks. Rust is the biggest reason why holes happen in the first place. Leaving a motorcycle in an area with a lot of moisture and where water can easily get access can significantly increase the chance of rust forming.
How to Find Holes
If you can’t see any holes on your fuel tank, but it is leaking, you need to shake the tank to see where exactly the fuel leaks. If you already separated the tank from your motorcycle, you should have left some fuel inside the tank, so you see where it leaks once you shake it.
Conclusion
A motorcycle fuel tank is a part in which the gasoline gets stored, and because of that, you need to take care of it and maintain it. Proper motorcycle care is vital to ensure that not only the fuel tank but also the entire motorcycle doesn’t get rusted. The rust that can get formed inside the tank can then reach other parts of the motorcycle fuel system, leading to other issues and making other parts malfunction. Luckily, you can prevent all this from happening if you take care of your fuel tank, and this article will certainly help you in that process.
We hope you enjoyed reading and learned a lot of helpful stuff that helped you repair your fuel tank.