Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R banner

1 - 9 of 9 Posts

·
Registered
Joined
·
1 Posts
Discussion Starter · #1 ·
Hello all, I bought a 2005 EX500 last fall and it started and ran when I bought it and ran for about an hour after I got it home and then it wouldn't turn over. After inspecting the tank I noticed a good amount of rust. I tried cleaning it with vinegar (looked pretty good inside) and drying it with a heat gun then using POR-15 to seal it but after 92 hours it was like a croissant, very very flaky. I've taken an air gun to it for probably 3 or 4 hours and flakes are still blowing out. Tried rolling bbs and a chain as well.

There are no motorcycle shops local that offers sealing. I've thought about finding another tank but anything used appears rusty too. I thought about maybe a type of bladder to go in the tank. I'm really feeling lost at this point. Does any one have any ideas? Maybe a shop that I could ship to for resealing?
 

·
Premium Member
Joined
·
3,792 Posts
If you can find a radiator shop, they used to do rust removal for motorcycle tanks, some offer sealing as well.

I have used muriatic acid, with excellent results. You can find it at most hardware stores by the gallon.
 
  • Like
Reactions: Davenay67

·
Registered
Joined
·
593 Posts
Google motorcycle tank rust removal electrolysis.
 

·
Super Moderator
Joined
·
15,401 Posts
FYI.....OP screwed up the prep sequence in his POR-15 efforts. Requires proper cleaning, followed by application of an etching agent, then total drying prior to final application of product. Vinegar is NOT recognized by POR as a proper prep cleaning agent.....period.

I've done 4-5 fully successful treatments explicitly following printed POR directions. Pic of drying sequence (prior to final application)

tankporn.jpg
 

·
Super Moderator
Joined
·
6,620 Posts
Following directions is key.
 

·
Registered
2001 EX500R
Joined
·
36 Posts
You can go the ghetto fab route like me. I had the same lots of rust scale in the nether regions of my tank. I filled it with coca cola, tossed in a bunch of nuts and bolts(hindsight better to use a link of chain). Shook the tank like a mad man until I couldn't. Multiple times. Drained coca cola. Took extra care to get all the nuts and bolts out. Rinsed with diluted vinegar and water. Rinsed with soap and hot water 3 times and then just hot water twice and then blasted the inside with WD40. Shook it to coat the insides and let it sit and drain. Clean the neck up of the surface rust from the vinegar, reinstall cap and petcock. Filled with high octane and added some water removal additive. So far so good. I peak inside almost daily to make sure she isn't rusting back.
 

·
Registered
Joined
·
1,489 Posts
I filled it with coca cola, tossed in a bunch of nuts and bolts(hindsight better to use a link of chain).
thread them unto a piece of strong string about 30 or 40 should do. then just hook out the string (no lost nuts)
I did mine similar method.
cap and petcock off. blank off the holes. half a litre of cider vinegar 40 nuts (on a string) shake like crazy (perhaps 20 mins) covering all areas of the tank. take out nuts and drain. then refill to the brim with said cider vinegar leave to stand. (left mine 4 days) drain out contents. leave to drain. for 1 hr. add 1/2 a litre of Paraffin (kerosene) wash out. replace the petcock and filler cap. add a gallon of premium fuel give it a shake. refit the tank.
the nuts knock off the rust. the cider vinegar cleans and kills the the rest of the rust. the paraffin washes out the cider vinegar. and any droplets of paraffin left mix with the fuel. job done lengthy but works. did mine 4 years ago still no rust inside.
 

·
Premium Member
1997 Kawasaki Ninja 500
Joined
·
252 Posts
I've thought about finding another tank but anything used appears rusty too. I thought about maybe a type of bladder to go in the tank. I'm really feeling lost at this point. Does any one have any ideas?
Where are you located? A member may be able to help you with acquiring a used tank depending on location.
 
1 - 9 of 9 Posts
Top