Gas tank leak - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 9 Old 10-20-2008, 01:28 PM Thread Starter
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Gas tank leak

Was out riding Saturday. It came to an abrupt, unpleasant end when I noticed gas trickling down the side of my bike. Found about a 1.5 cm crack at what i suspect to be a weld line. If you imagine a line from the center of the gas cap to the base of the tank just under the seat, the crack is about 1 cm from the base along that line. Anyone had a similar problem? Is there any use in trying to have the tank repaired, or should I consider it a loss, and buy an IMS tank?
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post #2 of 9 Old 10-20-2008, 01:38 PM
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Never heard of that. Tank can be repaired, but, for me, all the other welds would be suspect.

There are a couple of guys parting out bikes right now if you'll search.

Of course, it's a good excuse for an IMS tank if you want one.
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post #3 of 9 Old 10-20-2008, 01:44 PM
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wow that's to bad what year is your bike? I noticed something about my 06 when you squeeze the tank with your leg's while riding there is a lot of vibration. I had questioned if that would cause fatigue and stress cracking that is a big tank.
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post #4 of 9 Old 10-21-2008, 03:09 PM Thread Starter
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Bike is an '05. I suspect vibration plays some part; bad weld completes the cast. I also have a Corbin seat that abuts against the tank more tightly than stock. I suspect the seat revealed an inherent weakness in my bike. IMS tank, here I come.
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post #5 of 9 Old 10-21-2008, 10:33 PM
 
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just installed my ims tank..Though there is only one other option I found for a plastic tank i have to say the ims tank kinda fit like crap..looks great,,not real happy with the fit and finish,,however I bought it for function,,not fashion..
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post #6 of 9 Old 11-16-2008, 01:54 PM
 
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Dude..... turn the tank upside down (drain if leaking from cap), clean leak area with carb cleaner, wipe dry, cover crack area with an 1/8-1/4" thick layer of JB Weld and save your money for gas.
Mrs. baboon's gs500e's tank was fixed that way over a year ago and no problems to date.
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post #7 of 9 Old 04-14-2010, 09:52 AM
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I think my tank has a leak in the same spot. Its the tab that holds the rear of the tank down. I have tried JB and Seal All (my best fix it goops) and nothing has stopped it. Can this be welded?
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post #8 of 9 Old 04-14-2010, 11:20 AM
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Quote:
Originally Posted by willmo454 View Post
I think my tank has a leak in the same spot. Its the tab that holds the rear of the tank down. I have tried JB and Seal All (my best fix it goops) and nothing has stopped it. Can this be welded?
It can be welded, but it's going to need paint and BE VERY CAREFUL before welding.. You'll need to get all the gas fumes out of the tank before welding..

Safety first!!
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post #9 of 9 Old 04-16-2010, 09:10 PM Thread Starter
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My spot was a bit different. It was on the midline seam about 1 inch above the tab that holds the tank down. I figure it was a faulty weld worsened by the Corbin seat (presses against the tank harder than the stock seat).
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