Welp, it happened: Put a hole in my tank

Cra1g · August 5th, 2016, 05:46 PM

I've heard the stories before, but yet it happened to me today. The right-side top fairing bolt put a hole in my gas tank on my '07 Ninja 250.

I've heard JB weld deteriorates over time and isn't a great fix.

Professional welding is an option, but I'm told you have to completely clean the inside of the tank so that there's no gas left. Plus, you have to end up repainting it?

Lastly, just replacing the gas tank is probably the best option? I'm sure I can find one on eBay or Craigslist.

Any thoughts?

RacinNinja · August 5th, 2016, 05:49 PM

Quote:

Originally Posted by Cra1g

I've heard the stories before, but yet it happened to me today. The right-side top fairing bolt put a hole in my gas tank on my '07 Ninja 250.

I've heard JB weld deteriorates over time and isn't a great fix.

Professional welding is an option, but I'm told you have to completely clean the inside of the tank so that there's no gas left. Plus, you have to end up repainting it?

Lastly, just replacing the gas tank is probably the best option? I'm sure I can find one on eBay or Craigslist.

Any thoughts?

They make a metal epoxy for repairing gas tanks. It's not cheap though, I think $60 for the kit.

Depends on what you can get a new tank for.

Cra1g · August 5th, 2016, 05:56 PM

Quote:

Originally Posted by RacinNinja

They make a metal epoxy for repairing gas tanks. It's not cheap though, I think $60 for the kit.

How would I go about applying it? There's the metal tab that sort of blocks the hole, making it hard to get to: http://imgur.com/a/2viMs

juliusmichaelhonrada · August 5th, 2016, 06:03 PM

Quote:

Originally Posted by Cra1g

How would I go about applying it? There's the metal tab that sort of blocks the hole, making it hard to get to: http://imgur.com/a/2viMs

the bolt will push the epoxy where it made the hole

RacinNinja · August 5th, 2016, 06:04 PM

Quote:

Originally Posted by Cra1g

How would I go about applying it? There's the metal tab that sort of blocks the hole, making it hard to get to: http://imgur.com/a/2viMs

You get some popsicle sticks, some sandpaper, some glue to stick the sand paper to the stick, some alcohol, and a whole crap ton of patience!!

This is a smaller container and much cheaper. I've used it before and it works well! I'd trust it.

https://www.amazon.com/Marine-Tex-Ep.../dp/B0014419V0

RacinNinja · August 5th, 2016, 06:04 PM

Oh, and by the way, if you put a hole in the gas tank, you used the wrong fairing bolt in that hole. They are different lengths....check before you insert!!

Cra1g · August 5th, 2016, 06:11 PM

Quote:

Originally Posted by RacinNinja

You get some popsicle sticks, some sandpaper, some glue to stick the sand paper to the stick, some alcohol, and a whole crap ton of patience!!

This is a smaller container and much cheaper. I've used it before and it works well! I'd trust it.

https://www.amazon.com/Marine-Tex-Ep.../dp/B0014419V0

So this stuff will work with the gas tank's metal and won't be affected by the gasoline?

What's the sandpaper and alcohol for? Prepping the area I'm guessing? Anything special I need to do? Any tips to seal it the best I can? Sorry for all the questions!!

Quote:

Originally Posted by RacinNinja

Oh, and by the way, if you put a hole in the gas tank, you used the wrong fairing bolt in that hole. They are different lengths....check before you insert!!

All the bolts are the same length..

alex.s · August 5th, 2016, 06:11 PM

probably cheapest to just get a used tank...

RacinNinja · August 5th, 2016, 06:13 PM

Quote:

Originally Posted by Cra1g

So this stuff will work with the gas tank's metal and won't be affected by the gasoline?

What's the sandpaper and alcohol for? Prepping the area I'm guessing? Anything special I need to do? Any tips to seal it the best I can? Sorry for all the questions!!

All the bolts are the same length..

Hmmm....Ok. Thought the uppers were shorter. Might want to shorten it so it doesn't happen again....

Anyway, sand the paint away around the hole down to bare metal. Alcohol to clean up sanding residue. Apply epoxy EXACTLY per instructions.

Yes, it's gasoline safe and resistant. Will work just fine.

Manu's FAQ; http://www.marinetex.com/Marine-Texf...r-Marine-44867

Is Marine-Tex Epoxy Putty resistant to gasoline and diesel?
Yes, Marine-Tex Epoxy Putty is resistant to gasoline and diesel.

Cra1g · August 5th, 2016, 06:21 PM

Quote:

Originally Posted by alex.s

probably cheapest to just get a used tank...

I did a quick search and $100 is about the cheapest I could find, and that's with dents and scratches. Might as well spend $20 and try to patch it up myself.

Cra1g · August 5th, 2016, 06:44 PM

Quote:

Originally Posted by RacinNinja

Hmmm....Ok. Thought the uppers were shorter. Might want to shorten it so it doesn't happen again....

Anyway, sand the paint away around the hole down to bare metal. Alcohol to clean up sanding residue. Apply epoxy EXACTLY per instructions.

Would it be easier to cut off the bolt mounting tab thing? It would give me much better access to the hole and I wouldn't really need to use a screw there anyway--the fairing would hold just fine without it.

Z1R rider · August 5th, 2016, 10:05 PM

here's how I fixed it, not easy but it's permanent and won't mess up the paint job.

https://www.ninjette.org/forums/showthread.php?t=176379

jkv45 · August 6th, 2016, 06:13 AM

Quote:

Originally Posted by Cra1g

All the bolts are the same length..

They shouldn't be. That's why it punctured the tank.

http://faq.ninja250.org/wiki/How_do_...l_tank,_etc%3F

"Warnings first, AND PAY ATTENTION

1. The bolts that go from the upper fairing into the gas tank are very size-sensitive.

We recommend using only OEM Kawasaki bolts in that application. On older bikes, if you used one of the bolts from the bottom in the top fairing hole, you would puncture the tank, making it leak gas and making you replace it. Late-model bikes SHOULD have bolts that are all equal length, but earlier ones had some that were longer than others. Be careful and organized. Certainly don't use anything longer than the OEM length of 6x18.

If you have some fairing bolts that are longer than others, replace them".

Cra1g · August 6th, 2016, 06:44 AM

Quote:

Originally Posted by jkv45

They shouldn't be. That's why it punctured the tank.

That's understandable, but I wonder why all my bolts are the same lengths?

CC Cowboy · August 6th, 2016, 07:10 AM

Quote:

Originally Posted by RacinNinja

You get some popsicle sticks, some sandpaper, some glue to stick the sand paper to the stick, some alcohol, and a whole crap ton of patience!!

Isn't that what the alcohol is for?

RacinNinja · August 6th, 2016, 07:23 AM

Quote:

Originally Posted by CC Cowboy

Isn't that what the alcohol is for?

Cra1g · August 6th, 2016, 07:57 AM

http://i.imgur.com/boKlrGS.jpg

Sanded it down mostly. Still going to attack it some to make sure I absolutely got it all, but it honestly didn't take that long using 150-grit sandpaper--maybe 10 minutes or so.

RacinNinja · August 6th, 2016, 08:24 AM

Quote:

Originally Posted by Cra1g

http://i.imgur.com/boKlrGS.jpg

Sanded it down mostly. Still going to attack it some to make sure I absolutely got it all, but it honestly didn't take that long using 150-grit sandpaper--maybe 10 minutes or so.

Cra1g · August 6th, 2016, 07:22 PM

Alright, completely sanded down and cleaned. Ready for the epoxy stuff to get here on Monday..

nickjpass · August 6th, 2016, 08:54 PM

Replace the tank, repair the current one in your spare time for a back up.

Chocula · August 6th, 2016, 09:50 PM

Kawasaki issued a recall for this exact issue. It is likely you can get it replaced by your local dealer. At the very least, it is worth calling your dealer and talking to them about the issue. Have your VIN number handy and they should be able to look up the recall.

Cra1g · August 7th, 2016, 05:41 AM

Quote:

Originally Posted by Chocula

Kawasaki issued a recall for this exact issue. It is likely you can get it replaced by your local dealer. At the very least, it is worth calling your dealer and talking to them about the issue. Have your VIN number handy and they should be able to look up the recall.

I believe the 2007 model isn't included in the recall.

Chocula · August 7th, 2016, 06:28 PM

You can check your VIN at http://www-odi.nhtsa.dot.gov/recalls...l_ID=07V003000

Even if yours is not subject to the recall, it is showing the same problem as covered by the recall and I would be VERY surprised if Kawasaki USA would not cover this. Personally, I would be making phone calls and writing letters until they sent me a new tank. Of course it is your bike, you may choose to handle this any way you like.

The NHTSA shows the following models covered by this recall.

Vehicle Make Model Model Year(s)

KAWASAKI EX250F18 2004
KAWASAKI EX250F18L 2004
KAWASAKI EX250F19 2005
KAWASAKI EX250F19L 2005
KAWASAKI EX250F6F 2006
KAWASAKI EX250F6FL 2006
KAWASAKI EX250F7F 2007
KAWASAKI EX250F7FL 2007

Cra1g · August 8th, 2016, 10:55 AM

Quote:

Originally Posted by Chocula

You can check your VIN at http://www-odi.nhtsa.dot.gov/recalls...l_ID=07V003000

Even if yours is not subject to the recall, it is showing the same problem as covered by the recall and I would be VERY surprised if Kawasaki USA would not cover this. Personally, I would be making phone calls and writing letters until they sent me a new tank. Of course it is your bike, you may choose to handle this any way you like.

The NHTSA shows the following models covered by this recall.

Vehicle Make Model Model Year(s)

KAWASAKI EX250F18 2004
KAWASAKI EX250F18L 2004
KAWASAKI EX250F19 2005
KAWASAKI EX250F19L 2005
KAWASAKI EX250F6F 2006
KAWASAKI EX250F6FL 2006
KAWASAKI EX250F7F 2007
KAWASAKI EX250F7FL 2007

So my model is listed there, but when I went to check my VIN, it says there's no recalls.

Honestly, I'm not too determined about getting a whole new tank. I think the method that RacinNinja mentioned (and what I'm in the middle of doing) will do just fine.

Cra1g · August 9th, 2016, 05:08 AM

Applied the Marine Tex this morning and was fairly simple and straightforward. Now waiting 24 hours for it to cure! The anticipation is killing me..

JohnnyBravo · August 9th, 2016, 11:34 AM

I'm trying to work on my patience... I want it now :rotfl:

Cra1g · August 10th, 2016, 02:33 PM

Epoxy stuff is cured and ready to go, so I filled the tank back up and will await to see if it leaks or not. Got a towel ready just in case..

JohnnyBravo · August 11th, 2016, 07:44 AM

Looks great!

Cra1g · August 11th, 2016, 08:01 AM

I let it sit overnight and there were no leaks! So I'll start the process of putting everything back together.

I also found out that the four bolts that hold the radiator in place were all missing, which means it was probably just hanging by the hoses. Had to go to the hardware store to get new bolts. Not sure if the shop I took it to a while ago forgot to put them back on or what...

JohnnyBravo · August 11th, 2016, 08:08 AM

Least it all sorted out!

jkv45 · August 11th, 2016, 09:38 AM

Quote:

Originally Posted by Cra1g

I let it sit overnight and there were no leaks! So I'll start the process of putting everything back together.

I also found out that the four bolts that hold the radiator in place were all missing, which means it was probably just hanging by the hoses. Had to go to the hardware store to get new bolts. Not sure if the shop I took it to a while ago forgot to put them back on or what...

You would think they would have at least caught it. What work did you have done at the shop?

Cra1g · August 11th, 2016, 10:01 AM

Quote:

Originally Posted by jkv45

You would think they would have at least caught it. What work did you have done at the shop?

Carb clean/sync and valve adjustment.

jkv45 · August 11th, 2016, 10:46 AM

Quote:

Originally Posted by Cra1g

Carb clean/sync and valve adjustment.

Probably the shop then. If you are smart you put all of the fasteners from one area together in a tray so you know when everything you removed is replaced.

Figures. It's really hard to find a good Tech these days.

soonerbillz · August 15th, 2016, 01:33 PM

So i have been down this path..
My permanent cure was to eliminate the chance of leaks by using the JB weld marine grade gas tank repair epoxy and filling the entire bolt hole and then before it cured screwing a stud into the hole. I then put a thin flange nut onto the stud with a bit more epoxy and tightened it down. Now my fairing is held on by another flange nut on the stud.. on removal only the nut comes off.. the stud stays put.
I can remove and install with no worries of punching a hole in the tank again...

August 5th, 2016, 05:46 PM	#1
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	Welp, it happened: Put a hole in my tank I've heard the stories before, but yet it happened to me today. The right-side top fairing bolt put a hole in my gas tank on my '07 Ninja 250. I've heard JB weld deteriorates over time and isn't a great fix. Professional welding is an option, but I'm told you have to completely clean the inside of the tank so that there's no gas left. Plus, you have to end up repainting it? Lastly, just replacing the gas tank is probably the best option? I'm sure I can find one on eBay or Craigslist. Any thoughts?

August 5th, 2016, 06:04 PM	#6
RacinNinja Vintage Screwball Name: B Location: Washington Join Date: Feb 2016 Motorcycle(s): 2011 Ninja 250, 2008 Ninja 250, 2019 KTM 1290SDR, 2017 FZ10 Posts: A lot. MOTM - Mar '16	Oh, and by the way, if you put a hole in the gas tank, you used the wrong fairing bolt in that hole. They are different lengths....check before you insert!! __________________________________________________ Goin' fast on slow bikes!

August 5th, 2016, 06:11 PM	#8
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	probably cheapest to just get a used tank... __________________________________________________

August 5th, 2016, 10:05 PM	#12
Z1R rider ninjette.org certified postwhore Name: Roger Location: Mitchell, South Dakota Join Date: Apr 2014 Motorcycle(s): 1978 Z1R, 1999 EX250 Posts: A lot. MOTY - 2018, MOTM - Oct '16	here's how I fixed it, not easy but it's permanent and won't mess up the paint job. https://www.ninjette.org/forums/showthread.php?t=176379 __________________________________________________
	1 out of 1 members found this post helpful.

August 6th, 2016, 07:57 AM	#17
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	http://i.imgur.com/boKlrGS.jpg Sanded it down mostly. Still going to attack it some to make sure I absolutely got it all, but it honestly didn't take that long using 150-grit sandpaper--maybe 10 minutes or so.
	1 out of 1 members found this post helpful.

August 6th, 2016, 07:22 PM	#19
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	Alright, completely sanded down and cleaned. Ready for the epoxy stuff to get here on Monday..
	2 out of 2 members found this post helpful.

August 6th, 2016, 08:54 PM	#20
nickjpass #squid Name: nickypoo Location: Five Guys Join Date: Jul 2011 Motorcycle(s): Track dedicated 2008 ZX6R Posts: A lot. MOTM - Jul '16	Replace the tank, repair the current one in your spare time for a back up. __________________________________________________

August 6th, 2016, 09:50 PM	#21
Chocula ninjette.org member Name: Chocula Location: California Join Date: Aug 2016 Motorcycle(s): Lots Posts: 24	Kawasaki issued a recall for this exact issue. It is likely you can get it replaced by your local dealer. At the very least, it is worth calling your dealer and talking to them about the issue. Have your VIN number handy and they should be able to look up the recall.
	1 out of 1 members found this post helpful.

August 7th, 2016, 06:28 PM	#23
Chocula ninjette.org member Name: Chocula Location: California Join Date: Aug 2016 Motorcycle(s): Lots Posts: 24	You can check your VIN at http://www-odi.nhtsa.dot.gov/recalls...l_ID=07V003000 Even if yours is not subject to the recall, it is showing the same problem as covered by the recall and I would be VERY surprised if Kawasaki USA would not cover this. Personally, I would be making phone calls and writing letters until they sent me a new tank. Of course it is your bike, you may choose to handle this any way you like. The NHTSA shows the following models covered by this recall. Vehicle Make Model Model Year(s) KAWASAKI EX250F18 2004 KAWASAKI EX250F18L 2004 KAWASAKI EX250F19 2005 KAWASAKI EX250F19L 2005 KAWASAKI EX250F6F 2006 KAWASAKI EX250F6FL 2006 KAWASAKI EX250F7F 2007 KAWASAKI EX250F7FL 2007
	1 out of 1 members found this post helpful.

August 9th, 2016, 05:08 AM	#25
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	Applied the Marine Tex this morning and was fairly simple and straightforward. Now waiting 24 hours for it to cure! The anticipation is killing me..
	1 out of 1 members found this post helpful.

August 9th, 2016, 11:34 AM	#26
JohnnyBravo Certifiable nontundrum Name: Harper Location: NC Milkshake stand Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much. MOTM - Sep '13, Sep '16	I'm trying to work on my patience... I want it now :rotfl: __________________________________________________

August 10th, 2016, 02:33 PM	#27
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	Epoxy stuff is cured and ready to go, so I filled the tank back up and will await to see if it leaks or not. Got a towel ready just in case..
	2 out of 2 members found this post helpful.

August 11th, 2016, 07:44 AM	#28
JohnnyBravo Certifiable nontundrum Name: Harper Location: NC Milkshake stand Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much. MOTM - Sep '13, Sep '16	Looks great! __________________________________________________

August 11th, 2016, 08:01 AM	#29
Cra1g ninjette.org member Name: Craig Location: San Luis Obispo, CA Join Date: Jul 2016 Motorcycle(s): 2014 Ninja 300 ABS, 2007 Yamaha FZ6 Posts: 210	I let it sit overnight and there were no leaks! So I'll start the process of putting everything back together. I also found out that the four bolts that hold the radiator in place were all missing, which means it was probably just hanging by the hoses. Had to go to the hardware store to get new bolts. Not sure if the shop I took it to a while ago forgot to put them back on or what...
	2 out of 2 members found this post helpful.

August 11th, 2016, 08:08 AM	#30
JohnnyBravo Certifiable nontundrum Name: Harper Location: NC Milkshake stand Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much. MOTM - Sep '13, Sep '16	Least it all sorted out! __________________________________________________

August 15th, 2016, 01:33 PM	#34
soonerbillz ninjette.org member Name: Scott Location: Claremore Oklahoma Join Date: May 2014 Motorcycle(s): 2003 Ex250 Posts: 165	So i have been down this path.. My permanent cure was to eliminate the chance of leaks by using the JB weld marine grade gas tank repair epoxy and filling the entire bolt hole and then before it cured screwing a stud into the hole. I then put a thin flange nut onto the stud with a bit more epoxy and tightened it down. Now my fairing is held on by another flange nut on the stud.. on removal only the nut comes off.. the stud stays put. I can remove and install with no worries of punching a hole in the tank again... __________________________________________________ Soonerbillz - Soonerbillz Racing News - Soonerbillz Trading Post
	1 out of 1 members found this post helpful.

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