gas tank leaking 01 250ex - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 4 (permalink) Old 07-18-2008, 02:32 PM Thread Starter
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gas tank leaking 01 250ex

There was some slight damage to the tank where the fearing connects. The tank has a little clip welded on it.

I guess it was bent, someone bent it back then over the years a leak at the clip weld formed.

My question is can this be rewelded? Or do I need a new tank (300-500$)

I assume that if there is no fuel in the tank and tank is dried any radiator shop should be able to weld this.

However, the motorcycle shop it is at now says, "no you can't weld a fuel tank" They urged me not to ride it because it might leak and catch fire.

mind you the leak isn't that bad and if the fuel is 1/2-1 gallon even sloshing around shouldn't make it leak at that place.

I just need to get it home till I figure out what I need to do.

What ya'll think....
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post #2 of 4 (permalink) Old 07-18-2008, 03:25 PM
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You can weld up the gas tank. As long as its metal, you can weld it. How do you think they used to do gas tank repairs?

That being said, it's EXTREMELY DANGEROUS! Don't just waltz up and weld on it. Like you said it needs to be dried out / flushed / kept out for days, but even then its still a dangerous situation. I doubt most places would even do such a repair; you would need to find a place that specializes in gas tank repairs.

However, if you're cheap like me and your buddy won't let you borrow the welder, go grab some JB Weld and throw it on there. I had a leak in my gas tank that leaked like a race horse all the time, but I threw some JB Weld on there and it hasn't leaked a drop since. (1 month later, but for the 5 dollar price of a little bit of JB Weld, I don't think thats too bad)
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post #3 of 4 (permalink) Old 07-18-2008, 05:35 PM
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u can weld on it it's easy, just empty the gas out and let it dry for a few, then put some dry ice in there and the fog is heavier than the fumes and it fills the tank with co2 as the dry ice evaporates making it non flammable and weldable.


u can get a tank seal kit from POR15. part number is CTRK and has everything to do it... it'll take u a weekend to do it correctly.

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post #4 of 4 (permalink) Old 07-18-2008, 10:38 PM Thread Starter
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Originally Posted by kkim View Post
That's pretty good... they warn you not to ride or weld it in hopes you'll buy another tank through them?

As others have pointed out, it can be welded and just the fact you asked means that you should take it somewhere that repairs gas tanks on a regular basis. It can be dangerous if not done properly.

Oh... and find another shop to go to.

oh yeah, definitely going to do that. except i live in a small town ,, 20 minutes to other nearest shop.

The bastards I took it to here kind of own the market around here.

I'm going to pull the tank, let it dry out.. then take it to a shop and see what they can do..

I just want this bike good for my g/f. I don't want her having something unsafe..

I got it today and drove it back, he was like " whatever you want" , but you can't start it on our property LMAO
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