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Went down to get Connie's papers today and noticed someone had placed a large amount of absorbent pellets under and around her. Check the fuel tank and found 7 imperial gallons of fuel gone. And then noticed when I opened the tank, fuel streaming out from the left side of the tank almost right at the bottom. Closer inspection revealed a very tiny pinhole leak, as if someone had take a very fine awl and punch a hole in the tank. Even the missing paint is perfect circular. I have seen rotted out tanks go before, but never one this perfect. No rust in the tank that I can see, so not sure what happened. Question is, can it be repaired or am I looking at replacing the entire damned tank?

repairs can get expensive between the patch paint and making sure there's nothing else wrong elsewhere. Try to find a nice used one on ebay

Wow that sucks! Although it could have been a rock coming up and hitting it possibly?
If you can find someone good with body work they should be able to patch it without a problem.
Good luck with it man.

Repair is the easy part. Remove paint around leak. Then just fill with exhaust gas or water and braze (do not weld, brazing or solder will take a lot more vibration) Then pressure test. Problem is that it will ruin paint. (this may not work if tank is coated with Kreem or other inside sealer)

And Ceemes are you sure about 7 imps? That would be like 8-1/2 US.

slimcolo wrote:Repair is the easy part. Remove paint around leak. Then just fill with exhaust gas or water and braze (do not weld, brazing or solder will take a lot more vibration) Then pressure test. Problem is that it will ruin paint. (this may not work if tank is coated with Kreem or other inside sealer)

And Ceemes are you sure about 7 imps? That would be like 8-1/2 US.

guestimating, it hold 7.5 US gallons and only done 40 kilometre since I last filled it up.

storysunfolding wrote:repairs can get expensive between the patch paint and making sure there's nothing else wrong elsewhere. Try to find a nice used one on ebay

Looked already, found two for 97 and they want over C$150 for them....ouch

Shouldn't the tank on any year from like 1988 - 2008 fit on your bike?

Wrider wrote:Shouldn't the tank on any year from like 1988 - 2008 fit on your bike?

You mean 1986-2006 right?

I think Wrider is right. Time stood still for that bike for the 2 decades + it was produced for. I wouldn't think they changed the gas tank as that bigass tank was one of the main selling points of that bike. I would do a used tank search of all years and then make sure it is the same by checking the parts # against eachother on a microfische like the one here

http://fiche.ronayers.com/Index.cfm/Mod ... e/Kawasaki


Good luck!

Another option is to coat inside with Kreem or Red coat.

ceemes wrote:Looked already, found two for 97 and they want over C$150 for them....ouch

Is that a joke? If the tank is truely rusting through you're going to spend more than that to get it fixed, and painted again. At least you would around here...