fuel tank leak at bolt holes

focus101 · July 14th, 2013, 07:23 PM

long story short the last tank (one that came with the bike) was leaking at the upper bolt holes, now i got a new (used) tank in pretty good condition, but on the left side i has a small drop (only when its full and on the kick stand), now my ? is am i getting the wrong size bolts? whats the correct size??, the threads on the tank look good and non striped. (btw i have the tank off now and the bolts i had in there broke off inside smh) NEED HELP!!

thanks

shawn

baxtc1 · July 15th, 2013, 02:31 AM

Common problem with these bikes, using too long a bolt will punch a hole right through your tank. The correct length for the bolt is 18mm. The holes can be welded up, but will need someone who knows what they are doing.

focus101 · July 15th, 2013, 06:26 AM

i do know someone who can weld, what is he welding the hole itself or around it?? is there an alternate way i can get it welded??

Quote:

Originally Posted by baxtc1

Common problem with these bikes, using too long a bolt will punch a hole right through your tank. The correct length for the bolt is 18mm. The holes can be welded up, but will need someone who knows what they are doing.

az3200 · July 15th, 2013, 06:47 AM

my next door neighbor had a ninja 250 with the same problem. Used a bolt that was too long and put a hole in the tank. He used JB Weld to patch it up. It worked, for the remaining 2 months before he totaled the bike

spc2125 · July 15th, 2013, 07:23 AM

Im in a kind of similar situation... my gas cap is leaking fuel when i fill it up and itll spew out the top. I think ill eventually just buy one on ebay. It wont have the key on it anymore, but it'll be a nice little *farkle*.

You can also get the gas cap bolts on ebay (in different colors as well)

Not something im going to get but just an example
http://www.ebay.com/itm/Black-Billet...662f88&vxp=mtr

and the bolts
http://www.ebay.com/itm/Titanium-Gas...cb4cc7&vxp=mtr

focus101 · July 15th, 2013, 08:53 AM

where did he apply the jb weld at exactly?? on the bolts or around hole area around the tank?? i heard of someone on another forum said he did that same thing.

not to mention i have to drill to two parts to the bolt that broke off when i taking them out. their in the back of the hole though maybe i can use a small bolt??..

thanks for your input guy im new at the bike stuff but mechanically inclined..

baxtc1 · July 15th, 2013, 04:50 PM

If you have a look where the bolts go, you will see that they screw into a plate that is welded to the tank. Behind that plate should be solid wall of the fuel tank. Whatever you try to seal it with will need to go onto the tank behind that plate. If getting it welded, that plate will be removed, the hole welded and then the plate rewelded back into place. I had someone weld up a tank on a previous GPX 250 I had a few years ago, he didn't do so well, he welded it up good, but he didn't clear all the fumes properly and had a small pop as he waved the torch over. That small pop was enough to blow the tank out of shape. I accepted the risk when I asked him to do it and in this case I ended up having to buy another tank anyway. As I said, if you go the welding route, make sure the bloke doing it is careful and you should be right.

focus101 · July 16th, 2013, 10:19 AM

ok i see it now, what imma do is just use some jb weld to patch it up(just gotta see where to apply it at), plus my upper fairing is cracked (came like that) so imma do a semi naked/streetfighter look and rock with that for a little bit, these tanks is a pain in the rear end lol..

thanks guys

slickt0mmy · July 16th, 2013, 05:48 PM

I have a similar problem. Previous owner punched a hole through the tank and tried to patch it with JB Weld. Unfortunately, they completely screwed it up and pressed the plate down flush with the tank and put JB Weld over the whole assembly. Now the bolt threads right into the gas tank and acts like a plug to keep the gas in. This would be fine except for the fact that small amounts of gas still leak out through the threads.

It's not enough to be alarming but my tank is constantly wet on the left side and is starting to get a yellow stain where the gas is always seeping out.

Whichever engineer at Kawasaki that designed this whole system needs to be fired.

CZroe · May 26th, 2014, 09:02 PM

The plate has a nut welded to the back and is spot-welded in three places. There are dimples in the tank just deep enough to make room for the nuts.

I would not recommend welding on the tank (factory did it before it ever had gas in it). I believe even an 18mm bolt will puncture the tank without fairings and such between.

Another user here has since freed his with a spot weld cutter and then soldered a tiny bit of sheet metal over the hole. I tried the same thing and ended up cutting more holes in the tank because the plate would not free even after drilling through the plate.

gordonsimon · January 28th, 2016, 04:26 PM

made a permanent fix...see photos..used 3/4" brass finger pull, JB METAL PUTTY AND JB WELD...EMAIL ME IF YOU WANT ALL THE DETAILS, BUT THE PHOTOS SAY IT ALL. once it was in place, i then filled up the finger full with JB weld and turned tank upside down with the bolt in the hole (well greased) to complete the sealing just in case something get past the brass finger pull.

swarfman64 · January 29th, 2016, 04:23 AM

I had the same problem.
I cleaned and dried tank, wound a long bolt in to open out the hole into the tank. Grab a 6mm x 6mm long grub screw, coat it and the internal threads (using match stick or similar) with JB weld. make sure you work the JB into the threads, get it bonding. Screw the grub screw in till its about 10mm deep, If you go to far just fish it out of the tank and try again. That's it, let it cure. As the grub screw goes in it cleans the JB from the thread so you don't need to re-tap it. I did all of mine and no leaks in 3 years, and m tanks been on and off a billion times!

HoneyBadgerRy · January 29th, 2016, 08:30 AM

Quote:

Originally Posted by slickt0mmy

I have a similar problem. Previous owner punched a hole through the tank and tried to patch it with JB Weld. Unfortunately, they completely screwed it up and pressed the plate down flush with the tank and put JB Weld over the whole assembly. Now the bolt threads right into the gas tank and acts like a plug to keep the gas in. This would be fine except for the fact that small amounts of gas still leak out through the threads.

It's not enough to be alarming but my tank is constantly wet on the left side and is starting to get a yellow stain where the gas is always seeping out.

Whichever engineer at Kawasaki that designed this whole system needs to be fired.

My bike was in the exact same situation when I bought it, I sanded down some of the JB weld he had on it, got a american sized nylon bolt, coated in in jb weld, cross threaded it into the gas tank (when it was empty) and then coated the head of the bolt in JB weld, it no longer leaks.

Bowtie2Bimmer · January 29th, 2016, 08:45 AM

This is super helpful. the tank I just got off ebay leaks form both bolt holes. Looks like we will need to jb weld it before we use it.

Actually, we are Kreeming the tank. Would this plug up those holes?

agentbad · January 29th, 2016, 10:52 AM

Don't they have a recall on this tank?

RickM · January 29th, 2016, 11:03 AM

Quote:

Originally Posted by agentbad

Don't they have a recall on this tank?

They did have a recall on the tank. I don't think it's still active though

CaliGrrl · January 29th, 2016, 11:42 AM

They did have a recall on the tanks, and I just had mine inspected for it. Some bikes did have bolts that were too long, and would dent the tank causing a rust point/leak. The recall was issued in 2007. Check and see if you can get something covered under it- they might be able to work with you.

taz · February 3rd, 2016, 06:16 AM

this same topic seems to come upalot so i thoought i would put a link to a good fix. https://www.ninjette.org/forums/show...341#post860341

July 14th, 2013, 07:23 PM	#1
focus101 ninjette.org member Name: shawn Location: nj Join Date: May 2013 Motorcycle(s): 96 250 Posts: 65	fuel tank leak at bolt holes long story short the last tank (one that came with the bike) was leaking at the upper bolt holes, now i got a new (used) tank in pretty good condition, but on the left side i has a small drop (only when its full and on the kick stand), now my ? is am i getting the wrong size bolts? whats the correct size??, the threads on the tank look good and non striped. (btw i have the tank off now and the bolts i had in there broke off inside smh) NEED HELP!! thanks shawn

January 29th, 2016, 04:23 AM	#12
swarfman64 Master modder Name: Andrew Location: Australia Join Date: Jan 2014 Motorcycle(s): TURBO gpx250 99 CB250/500rs Sherco290 Trials Indian 1911big base (replica) Posts: 138	I had the same problem. I cleaned and dried tank, wound a long bolt in to open out the hole into the tank. Grab a 6mm x 6mm long grub screw, coat it and the internal threads (using match stick or similar) with JB weld. make sure you work the JB into the threads, get it bonding. Screw the grub screw in till its about 10mm deep, If you go to far just fish it out of the tank and try again. That's it, let it cure. As the grub screw goes in it cleans the JB from the thread so you don't need to re-tap it. I did all of mine and no leaks in 3 years, and m tanks been on and off a billion times! __________________________________________________ [B]Come and see my turbo ninja build, dyno build and other stuff at http://swarfman64.blogspot.com.au/20...rtia-dyno.html

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July 15th, 2013, 02:31 AM	#2
baxtc1 ninjette.org member Name: Robert Location: South of you blokes. Join Date: May 2013 Motorcycle(s): '92 GPX 250 (Gone and replaced with '08 V-Strom), 2005 Suzuki C50. Posts: 186	Common problem with these bikes, using too long a bolt will punch a hole right through your tank. The correct length for the bolt is 18mm. The holes can be welded up, but will need someone who knows what they are doing.

July 15th, 2013, 06:47 AM	#4
az3200 ninjette.org member Name: AZ Location: Orlando FL Join Date: Oct 2012 Motorcycle(s): 2002 Ninja 250 Posts: 213	my next door neighbor had a ninja 250 with the same problem. Used a bolt that was too long and put a hole in the tank. He used JB Weld to patch it up. It worked, for the remaining 2 months before he totaled the bike

July 15th, 2013, 07:23 AM	#5
spc2125 ninjette.org member Name: Steven Location: MA Join Date: May 2013 Motorcycle(s): 10 Ninja 250 Posts: 172	Im in a kind of similar situation... my gas cap is leaking fuel when i fill it up and itll spew out the top. I think ill eventually just buy one on ebay. It wont have the key on it anymore, but it'll be a nice little farkle. You can also get the gas cap bolts on ebay (in different colors as well) Not something im going to get but just an example http://www.ebay.com/itm/Black-Billet...662f88&vxp=mtr and the bolts http://www.ebay.com/itm/Titanium-Gas...cb4cc7&vxp=mtr

July 15th, 2013, 08:53 AM	#6
focus101 ninjette.org member Name: shawn Location: nj Join Date: May 2013 Motorcycle(s): 96 250 Posts: 65	where did he apply the jb weld at exactly?? on the bolts or around hole area around the tank?? i heard of someone on another forum said he did that same thing. not to mention i have to drill to two parts to the bolt that broke off when i taking them out. their in the back of the hole though maybe i can use a small bolt??.. thanks for your input guy im new at the bike stuff but mechanically inclined..

July 15th, 2013, 04:50 PM	#7
baxtc1 ninjette.org member Name: Robert Location: South of you blokes. Join Date: May 2013 Motorcycle(s): '92 GPX 250 (Gone and replaced with '08 V-Strom), 2005 Suzuki C50. Posts: 186	If you have a look where the bolts go, you will see that they screw into a plate that is welded to the tank. Behind that plate should be solid wall of the fuel tank. Whatever you try to seal it with will need to go onto the tank behind that plate. If getting it welded, that plate will be removed, the hole welded and then the plate rewelded back into place. I had someone weld up a tank on a previous GPX 250 I had a few years ago, he didn't do so well, he welded it up good, but he didn't clear all the fumes properly and had a small pop as he waved the torch over. That small pop was enough to blow the tank out of shape. I accepted the risk when I asked him to do it and in this case I ended up having to buy another tank anyway. As I said, if you go the welding route, make sure the bloke doing it is careful and you should be right.

July 16th, 2013, 10:19 AM	#8
focus101 ninjette.org member Name: shawn Location: nj Join Date: May 2013 Motorcycle(s): 96 250 Posts: 65	ok i see it now, what imma do is just use some jb weld to patch it up(just gotta see where to apply it at), plus my upper fairing is cracked (came like that) so imma do a semi naked/streetfighter look and rock with that for a little bit, these tanks is a pain in the rear end lol.. thanks guys

July 16th, 2013, 05:48 PM	#9
slickt0mmy ninjette.org member Name: Adam Location: Ohio Join Date: Jul 2012 Motorcycle(s): 2004 Ninja 250 Posts: 178	I have a similar problem. Previous owner punched a hole through the tank and tried to patch it with JB Weld. Unfortunately, they completely screwed it up and pressed the plate down flush with the tank and put JB Weld over the whole assembly. Now the bolt threads right into the gas tank and acts like a plug to keep the gas in. This would be fine except for the fact that small amounts of gas still leak out through the threads. It's not enough to be alarming but my tank is constantly wet on the left side and is starting to get a yellow stain where the gas is always seeping out. Whichever engineer at Kawasaki that designed this whole system needs to be fired.

May 26th, 2014, 09:02 PM	#10
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	The plate has a nut welded to the back and is spot-welded in three places. There are dimples in the tank just deep enough to make room for the nuts. I would not recommend welding on the tank (factory did it before it ever had gas in it). I believe even an 18mm bolt will puncture the tank without fairings and such between. Another user here has since freed his with a spot weld cutter and then soldered a tiny bit of sheet metal over the hole. I tried the same thing and ended up cutting more holes in the tank because the plate would not free even after drilling through the plate.

January 29th, 2016, 08:45 AM	#14
Bowtie2Bimmer ninjette.org member Name: TONY Location: JACKSONVILLE, FL Join Date: Jan 2016 Motorcycle(s): 2005 V-STROM 1000 Posts: 24	This is super helpful. the tank I just got off ebay leaks form both bolt holes. Looks like we will need to jb weld it before we use it. Actually, we are Kreeming the tank. Would this plug up those holes?

January 29th, 2016, 10:52 AM	#15
agentbad ninjette.org sage Name: bob Location: Earf Join Date: Apr 2013 Motorcycle(s): 2005 Ninja 250, 2006 SV650N Posts: 642	Don't they have a recall on this tank?

January 29th, 2016, 11:42 AM	#17
CaliGrrl ninjette.org certified postwhore Name: Kerry Location: Ventura, CA Join Date: Jan 2016 Motorcycle(s): Ninja650 Posts: A lot. MOTM - Apr '18, Apr '17, Apr '16	They did have a recall on the tanks, and I just had mine inspected for it. Some bikes did have bolts that were too long, and would dent the tank causing a rust point/leak. The recall was issued in 2007. Check and see if you can get something covered under it- they might be able to work with you.

February 3rd, 2016, 06:16 AM	#18
taz ???????????????? Name: T Location: no where Join Date: Feb 2016 Motorcycle(s): 2007 ninja 250, 14 ninja 300, 09 1125CR Posts: A lot. MOTM - May '17	this same topic seems to come upalot so i thoought i would put a link to a good fix. https://www.ninjette.org/forums/show...341#post860341