Help! 86' XT600 IVJ fuel tank problems.

**gcross** · #1 30 Aug 2002

Hi folks

In Budapest right now on UK to AUS trip. My tank decided that yesterday was a good day to start weeping fuel from its pores.

Further inspection and a prod or two have now resulted in an empty tank in dire need of repair or replacement. Have been advised to find tank specialist and have it welded as these tanks are very difficult to replace, apparently? Also advised to use petseal? a uk made product that can be used as an internal sealent once the holes are mended!?

As a mechanical novice I would appreciate any advice from knowledgable sources out there on the best way to sort this problem.

NB can anyone recommend a good mechanic/welder in the Budapest area?

Many thanks

Gordon Cross

**Grant Johnson** · #2 31 Aug 2002

A good welder can weld up the tank - just make sure to wash it with soapy VERY thoroughly first! Rinse for an hour or so with a garden hose stuck inside it.

If you can't find tank sealant locally go to the airport - they commonly use tank sealant for small planes, and you may be able to get someone there to either supply some, or do it for you. That may even be the place to get the welding done. Probably not as cheap but just as probably a better job given the standards they have to work to.

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Grant Johnson

Seek, and ye shall find.
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One world, Two wheels.
www.HorizonsUnlimited.com

**gcross** · #3 31 Aug 2002

thanks Grant will try and get a contact into the airport through a friend who works for Malev, hungarian national carrier.

Once again this site proves invaluable not only for practicle info but also for lifting the spirits when plans go awry.

hope your having fun in Canada

Gordon Cross

**mika** · #4 1 Sep 2002

hi gcross,
I am travelling on a 1VJ around the world since 99. Had the same problem in Sibiria and in Australia.

If you ask me, dont use the epoxid to cover the tank from inside. The expensive job lasted for six weeks in Australia.

Best is to get it solded (in German: loeten - Klaus, is this the correct english word ?) at a place where they repair radiators for cars.

And of course follow Grants advise

Have fun

Mika from Colombia

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**FredXTZ** · #5 2 Sep 2002

My friend Marcel repaired his tank at the 2 flanges where the top half is connected with a Locktite 2-component stuff.

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Fred, XTZ660, Holland.

**KlausXT600** · #6 2 Sep 2002

mika hit it almost - soldering is what he talks about.
for an emergency repair you can use also a good quality silicone sealing like 'würth silicone 250'. degreasing is very important.
regards
klaus

**gcross** · #7 8 Sep 2002

Thanks for your advice guys. Given that I ve still got a long way to go to get to Melbourne (I hope!) I opted for the "proper job" approach and had the tank opened up at the flanges by a specialist. Found a great bike store/mechanics on the M5 on the outskirts of Budapest. Thought this may be a useful ref. point for others (as there seems to be a few coming through this part of the world)

The contact details are >

Kiraly Lazlo
1196 Budapest
Nagykarosi Ut (M5)
TEL. 347 0352/3
www.motorrad.co.hu

So far so good on the tank job they did for me which involved cutting out all the old rot and putting in some beautiful new steel. The welding looks pretty good to me!

Hope to see some of you on the road in future and I hope not to have to call on your advice again too soon!

Thanks again

Gx

**EarlT** · #8 1 Oct 2007

I Did both of these Repairs.
They worked .
I know they held for more than 2 Years.
1.
1972 Ford Torino Station Wagon
Holes in Gas Tank ,
Rusted from inside out.
2 1989 Geo Metro
Holes in GasTank from 4Wheeling!

1. Clean area with Gasoline/Benzene/Solvent
or Dishwasher liquid and water-
make it Very Clean
at least 2" square.
put Solder paste on area.
Using a Propane/MAPP Gas/ Acetylene Torch
Heat up a 1" dia. Steel Rod(Tip of Rod cut at a 30*-45*angle)
Melt Solder to Seal Tank

2. Clean Area 2" Square
put Epoxy on Area,
Put a Small Coin(penny)
or what ever size Coin Fits,
Works Great!

**ssbon** · #9 2 Oct 2007

when i had a tank converted for sr500 the man in the welding shop purged the tank by using a car exhaust gases before welding hope this is of use to somebody steve