Rust Removal

• Restoring your rusted fuel tank beings with removing the rust from the inner surface. This is often done with an acidic chemical, such as muriatic acid, that will eat away at the corrosion then etch the inner metal surface to allow a stronger bond for a chemical fuel tank liner to adhere to. Although lining the tank is done on preference, cleaning and rust removal is a must. Start by pouring a handful of metal nuts into the tank and shaking it vigorously to loosen as much of the surface rust from the fuel tank's interior. Then, flush the tank out with water to remove any loose debris and fill it halfway with hot water. Slowly pour in a half-gallon of muriatic acid into the tank and top it off with warm water. Seal the tank off with a rubber stopper and let the acid go to work. Depending on the severity of your tank's rust problem, cleaning can take anywhere between two to four hours. When you're ready to drain the acidic solution, drain it into an appropriate container and immediately rinse out the tank with water, followed by a rise with gasoline. At this point, you can either re-install the tank on your Yamaha motorcycle and fill it with fresh gas or move onto the tank lining process.
  
  

Re-Lining the Fuel Tank

• Applying a coating of rust-inhibiting tank liner is a must for extremely rusted an/or leaking fuel tanks. Although these liners may not help major gaps in the tank, they can seal pinhole leaks created by corrosion. A quick trip to your local auto parts store will reveal a large selection of tank lining products, however, the most familiar product is Kreem's Fuel Tank Liner. To apply these liners, pour the solution into your fuel tank and slowly rotate the tank to coat all inner surfaces. Then place the tank in one position for a 10-minute period then reposition again until the tank is sufficiently coated. Drain any excess lining solution and allow the tank to air dry naturally before re-installing it onto your motorcycle.
  
  

Electrolysis

• Removing rust can also be done using a process called electrolysis, which involves placing your rusted tank into a solution of water and baking soda. Begin by filling the tank with the solution and attaching the tank to the negative (-) clamp from an automotive battery charger. Submerge the tank into a tub of baking soda and water. Next, place a bolt into the positive (+) clamp and drop it into the tub as well. Be sure that the bolt does not come into contact with the fuel tank to prevent a dangerous short-circuit. Let the tank sit in the charged solution for at least 24 hours, then unplug the battery charger and remove the fuel tank. Flush out the tank with water, followed by gasoline, then install it onto your motorcycle.