I just bought a 91 GS500E and the tank appears to have a small leak maybe along the seam. It has started to warp the rubber trim around the tank. I was wondering if there was any simple procedure to plug it. Also where could I get a replacement for the rubber. This site was a big reason I decided on a GS500 and any advice is greatly appreciated.

Pat D

can you take a photo of where the leak is. you may be able to get some sort of gas resistant filler to stop it, but rewelding might be the only way,

You need a compound like this to seal the tank but its effectiveness is limited by the size of the hole(s). If the hole proves to be too big find a good 2ndhand one, dont waste your time trying to find a welder prepared to patch the tank.........They all enjoy life far too much!!
http://www.frost.co.uk/item_Detail.asp?productID=8232&frostProductName=Fuel%20Tank%20Sealer%20(US%20Quart,%20946ml)

If you have it welded, don't forget to EMPTY THE GODDAMN TANK!!!

I noticed the postings for POR15. The site lists a kit for $39 that addresses small leaks and rust so I am thinking it may be worth a shot.  Let me know if I am off-base.

http://www.por15.com/PRODUCTS/COMPLETEKITS/CYCLETANKREPAIRKIT/tabid/103/Default.aspx


Thanks,
Pat D

Its safer than attempting to weld it!!!

That's the same kit that I used to seal my tank.  My 89 tank had a small rust hole near the "crap trap" area.  What I did was to clean out any rust really well, JB welded it, PORed the inside of the tank, and then used the leftover POR to cover the small JB weld area on the outside.  So far it has not leaked yet.  I don't remember when I did that, maybe a year ago or something like that.  I should really repaint the tank.  One day.

POR may not be the best ... its thick, and cannot be thinned out, it may not get into a tiny hole well enough to seal it.
I'd try Kreem, but the acid for Kreem is far worse than the acid for POR ... so your little hole may become a huge hole ...
I'd weld the MOFO for my $$$ but it may be harder for some people. Find someone with a tig and hev them weld it ... OH yea ... you need to locate it first, and yes get the gas out.
Cool.
Srinath.

Welding the tank is usually a workable solution, IF DONE CORRECTLY, By this I mean you weld the tank with it off the bike and full, OF WATER, that is the important part. Do not ever weld on an empty gas tank as fumes are much more likely to ignite than raw gas.

Quote from: ambisinister on July 10, 2006, 08:47:40 AM
Welding the tank is usually a workable solution, IF DONE CORRECTLY, By this I mean you weld the tank with it off the bike and full, OF WATER, that is the important part. Do not ever weld on an empty gas tank as fumes are much more likely to ignite than raw gas.

In fact, liquid gas isn't flammable. If you let a gallon of gas in a coffee can sit for a few days (weeks?) you can throw a lit cigarette into it. It's the vapors that are combustible. Seen a few mechanics do this, as they like to keep it around to clean their hands.