Persistent Minor Leak From Gas Tank

There is a very minor fuel leak associated with the locating tab at the underside-rear of the gas tank on my KZ1100A.
The tack welded(?) tab-plate seals for the most part, but sometimes a small amount of fuel escapes and drips from the tank onto the side cover and beyond.
I installed a small piece of ABS sheet over the tab to keep gasoline off the rubber frame insert, which otherwise gets ruined.

Looking for some suggestions, since the tank is drained and removed for the Winter and could be sent out for repair. I have not removed the petcock, fuel level mechanism, or the filler-cap, and there is a small amount of fuel still sitting in the tank.

If the leak is in an inconspicuous spot, you can strip the paint back a little and silver solder it. IF you don't want to damage the paint I recommend Caswell tank sealer. its a two part epoxy and MUCH beter than the one part sealers like Kreem or Redkote.

If it's a simple leak in a simple area JB Weld works great.

My thoughts are that if it's leaking a little now it will leak more later. I like the idea of a 2 part epoxy tank coating. I had an old BMW that had multiple rust holes along the bottom seam. After thoroughly cleaning I did the tank seal. That really did a very good job of stopping the leaks and preventing more. Been about 2 years and that bike is still leak free.

What DoctoRot said. Steer clear of RedKote and Kreem. I've had trouble with both even professionally applied.
I'm re-doing a tank with Caswell. Find a friend who needs a tank coated and you can do it for 1`/2 price.

Is there a good way to strip the redkote from 20 years ago out of a tank? Its chipping and dissolving (found a bunch of red pieces of ish at the bottom of the tank and in the carbs on the 77.400)

Dissolution with MEK (Methylethylketon) aka Butanon (C4 H8 O)



Other brand name

Ethylmethylketon
2-Butanon
Butan-2-on
Methylpropanon
Methylaceton

I had a leak I thought was coming from the tank. Turned out it was one of the petcock nipples was loose. Tapped it back in, no leak. Sometimes it's the stupid things that make us chase our tails.:lol:
Steve

POR-15. Follow the direction to the letter. Takes a few steps to do but worth the work. Did it to my '77 XS 650 Standard tank. Works great. It's a tough lining.

If the tank is structurally sound, then an epoxy will probably suffice.
I repaired a small leak on a fuel level switch with Permatex liquid metal. It's a 1-part epoxy that comes in a tube, so no mixing. The leak was at the fuel switch itself, not the o-ring where it seals against the tank. The repair was done several years ago. no leaks.

This should take care of it. Welded and checked for leaks.
Opinions on the weld appearance welcome.

Mmmmm sugar.


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