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To repair a motorcycle tank, turn off the tank, remove hoses and electronics, and drain the fuel. Allow the tank to dry and check for recalls. Welding may be necessary, and dents can be fixed with a dent puller or putty.
The two most common types of motorcycle tank repair needed are dent and puncture repair, and minor leak repair. The first step in solving these problems is to turn off the tank, remove the hoses and electronics that run to the tank, and safely remove the tank from the motorcycle. Almost all motorcycle tank repairs will require you to drain the fuel tank to prevent fire or other safety concerns, so have a container ready so you can safely and efficiently drain the fuel. Try to avoid getting gasoline on the paint on the tank, as this can damage the tank’s finish.
Once the tank has been completely emptied of fuel, allow it to dry with the cap open to allow fumes to escape. Motorcycle tank repairs using a torch cannot be done if fuel or vapors are present in the tank. While the tank is drying out, it may be a good decision to check with the manufacturer to find out if there have been any recalls on the tank or other parts of the bike. This step can save you the hassle of having to repair the tank. If the manufacturer has not recalled, consult their recommendations for repair methods and products, if applicable.
Some motorcycle tank repairs may require you to do some welding with a torch. If you’ve never done this before, it’s best to hire a professional or do it yourself under the supervision of someone with significant experience. Welding is not an easy process, so if you haven’t done it before, you risk further damage to the tank. Stripping the paint from the affected area is almost always necessary to ensure that the weld can be done correctly, so be sure to be prepared for the costs of repainting the tank as well.
Motorcycle tank repairs that involve repairing dents can sometimes be done without removing the tank from the bike. A dent puller can be purchased at an auto parts store, and this tool will help the repairman pull dents out of the tank using suction. Smaller dents may need to be filled with putty and then sanded, but larger dents can usually be fixed with the dent puller. A dent puller may leave some creases or irregularities, so additional repair may be necessary.
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