How to Reline a Motorcycle Gas Tank
- 1). Turn off the fuel valve, located below the left side of the gas tank, using the fuel valve selector lever. Turn the lever to the "On" position, if the fuel valve has a "Pri" or "Prime" setting. Skip this step if you are working on a fuel-injected motorcycle.
- 2). Unbolt the gas tank from the motorcycle with a socket wrench. Lift the gas tank off of the motorcycle's frame, then pull the fuel hose off of the fuel valve or fuel pump outlet. Unplug the fuel level sender and fuel pump connectors from the bottom of the gas tank, if equipped. Lay the gas tank on a clean, level work area.
- 3). Push a 3-foot length of rubber fuel hose onto the fuel valve or fuel pump outlet, then place the opposite end of the hose in a 5-gallon gas can. Turn the fuel valve selector arm to the "Pri" or "Prime" position to drain the gas tank. Alternatively, connect a 12-volt battery to the fuel pump connector to drain the gas tank.
- 4). Remove the gas cap and fuel valve or fuel pump from the gas tank, using an Allen or socket wrench. Seal the fuel valve or fuel pump port with a rubber cap.
- 5). Cover the painted outer surface of the gas tank with 2-inch-wide painter's tape, leaving only the gas tank filler neck uncovered. Cover the painter's tape with plastic sheeting, then tape the sheeting to the gas tank with plastic tape.
- 6). Drop a handful of 1/4-inch nuts into the gas tank through the filler neck. Cover the gas tank filler neck with a rubber cap. Shake the gas tank for at least 10 minutes to loosen rust deposits from the gas tank's inner surface. Remove the rubber cap from the filler neck and shake the nuts and loosened rust out from the gas tank.
- 7). Pour 1 quart of acetone into the gas tank through the filler neck. Cover the filler neck with the rubber cap. Shake the gas tank for 5 minutes to disperse the acetone through the tank. Remove the rubber cap, then carefully empty the tank into a plastic container.
- 8). Empty the bottle of acid bath solution into the gas tank through the filler neck and cover the filler neck with a rubber cap. Set the gas tank aside for 3 hours, then tilt the gas tank in a different angle and let it sit for another 3 hours. Continue until the entire inner surface of the gas tank has been bathed in the acid solution. Remove the rubber cap and empty the acid bath solution into a plastic container.
- 9). Pour 1 quart of acetone into the gas tank through the filler neck to rinse away the acid bath solution. Cover the filler neck with the rubber cap. Shake the gas tank for 5 minutes to disperse the acetone through the tank. Remove the rubber cap, then carefully empty the tank into a plastic container.
- 10
Pour the entire bottle of sealing solution into the gas tank through the filler neck. Cover the filler neck with a rubber cap. Roll the gas tank with your hands to coat the entire inner surface of the gas tank in the sealing solution. Remove the rubber cap and pour the sealing solution back into its bottle, using a funnel. Remove the rubber cap from the fuel valve or fuel pump port, then let the sealing solution cure for a 48 to 72 hours. Apply a second coat of sealing solution, if desired. - 11
Peel the plastic sheeting and painter's tape off of the gas tank. Reinstall the gas cap and fuel valve or fuel pump, using an Allen or socket wrench. Reconnect the fuel level sender and fuel pump connectors to the bottom of the gas tank. Push the fuel hose onto the fuel valve or fuel pump outlet. Reinstall the gas tank onto the motorcycle, using a socket wrench.
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