Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech

Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 30 Aug 2002
Registered Users
New on the HUBB
Join Date: Apr 2002
Location: London,UK
Posts: 7
Help! 86' XT600 IVJ fuel tank problems.

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

Reply With Quote
Old 31 Aug 2002
Grant Johnson's Avatar
HU Founder
Veteran HUBBer
Join Date: Dec 1997
Location: Vancouver BC Canada
Posts: 4,561
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.

Grant Johnson

Seek, and ye shall find.


One world, Two wheels.
Grant Johnson

Seek, and ye shall find.


Inspiring, Informing and Connecting travellers since 1997!
Reply With Quote
Old 31 Aug 2002
Registered Users
New on the HUBB
Join Date: Apr 2002
Location: London,UK
Posts: 7
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

Reply With Quote
Old 1 Sep 2002
Gold Member
Veteran HUBBer
Join Date: Apr 2000
Location: RTW
Posts: 500
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

Reply With Quote
Old 2 Sep 2002
Registered Users
Veteran HUBBer
Join Date: Aug 2002
Location: Hendrik Ido Ambacht, Holland
Posts: 360

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

Fred, XTZ660, Holland.
Fred, XTZ660, Holland.
Reply With Quote
Old 2 Sep 2002
KlausXT600's Avatar
Registered Users
Veteran HUBBer
Join Date: Sep 2000
Location: Hamburg, Germany
Posts: 295
mika hit it almost - soldering is what he talks about.
for an emergency repair you can use also a good quality silicone sealing like 'w├╝rth silicone 250'. degreasing is very important.
Reply With Quote
Old 8 Sep 2002
Registered Users
New on the HUBB
Join Date: Apr 2002
Location: London,UK
Posts: 7
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

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


Reply With Quote
Old 1 Oct 2007
Registered Users
New on the HUBB
Join Date: Sep 2007
Location: Oregon
Posts: 4
Fuel Tank Repair

I Did both of these Repairs.
They worked .
I know they held for more than 2 Years.
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!
Reply With Quote
Old 2 Oct 2007
Registered Users
Veteran HUBBer
Join Date: Feb 2005
Location: uk
Posts: 146
welding fuel tanks

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
Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 17:48.