Any older KLR gas tanks rusted out-leaking ? - 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 5 Old 02-24-2019, 08:25 PM Thread Starter
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Join Date: Feb 2019
Location: S. Texas
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Any older KLR gas tanks rusted out-leaking ?

Just like anything else, if a metal gas tank on a mc sits w/ a little water in the bottom long enough it will want to rust out on the bottom, especially if there is a seam. Anyone experience this. Worth while to just replace the OEM w/ plastic tank if the has rust in it? Many yrs ago I have used the “cream” product to line metal tanks. A BMW I had come from the factory w/ red epoxy liner. Thanks for any replies.
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post #2 of 5 Old 02-25-2019, 09:40 AM
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yes they can, and will, rust. Usually particulate in the gas becomes a problem long before they rust through. Though both my KLR's tanks are fine, I changed them for IMS 6.6 gall units for other reasons (no rust, scratches or dents ever; rad protection without adding 12-14 lb crashbars; better ergos and the ability to check my fuel level from 20' away)

Dave
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post #3 of 5 Old 02-25-2019, 01:47 PM
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The lower forward 'wings' would be the area to check with a flash light for water & crud puddles which would promote rusting. Preferably with a near empty tank.

I had a crack develop between the rear mounting bracket and the base metal years ago. I used a NLA brand of tank sealant (Lubri-Tech SS Tank Sealant) to coat the interior. Due to the design of the KLR tank, one can't drain out the Excess sealant very well & apply 2 or 3 individual coatings. So I concentrated on 'layering' the excess sealant back & forth across the rear mounting bracket are.

Then I glued layers of inner tube strips on the frame spine pads to take ALL of the loading off of All 3 of the brackets! I highly recommend this to Everyone!
Still fluid tight.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #4 of 5 Old 02-27-2019, 05:45 PM
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Quote:
Originally Posted by pdwestman View Post
Then I glued layers of inner tube strips on the frame spine pads to take ALL of the loading off of All 3 of the brackets! I highly recommend this to Everyone!
Still fluid tight.
Are you essentially raising the spine pads to take the weight off the brackets? And by "all three brackets" do you mean the two side ones that slip around those round rubber bumpers, along with the rear one where the two bolts latch down under the seat?

2017 KLR in black
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post #5 of 5 Old 02-27-2019, 07:34 PM
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Yes & Yes, samuel.

Use some modeling clay or Play-doh to measure how much clearance you have between a near empty tank & the spine pads. You might be surprized how much height you may have to add.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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