2 ways to clean rust from gas tank

There are a couple of Filebase articles written about rust removal on this website. Click on "KZ Information" and then "Filebase", then "Not model Specific". Over 100 articles written by members or uploaded from others, about working on your bike.

another way.... electrolysis sodium carbonate and a battery charger, check the forum search

I did the bb method two years ago on my tank, and it worked perfectly. I went to Wal mart and bought a pack of 1000 bbs for around 5 bucks. Used blankets and cardboard in the dryer, tumbled it for about 45 minutes, flipped it around and repeated it.

The only downside was how really annoying it was to get those last few bbs out; din't think of a magnet.

I then passed the bbs on to a friend of mine, who did his tank with them.

Not only was it the cheapest method I could find, but it didn't put any harsh chemicals into the environment and the second use of the bbs by my friend means we recycled, too.

That's a winner in my book.

Evapo-Rust - I have tried all the above... and Evapo-Rust worked the best... and here is the absolute winner for me. Evapo-Rust is completely "friendly" - stick your hand in it, drop it on your paint no issues - when done with it dilute it and spray it on your lawn as fertilizer! This stuff is great. Each gallon will hold up to 1/2 lb of rust. I have prepared 4 tanks with this.

Here are the caveats - you can keep using it until it stops working. One tank I did had a good deal of gas sludge in it... it contaminated the Evapo-Rust and i was still able to use it on 3 tanks, but I disposed of it through HazMat since it has so much petro visible in it.