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Old 07-05-2012, 12:55 PM   #21
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nemisis714's Avatar
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
Since my keys went missing 2 weeks ago, my only key for the bike went missing with it.... I just got the ignition back from the locksmith. It cost me $40.44 to get a new key cut from the ignition with 2 spares... next step on that path is to get the gas tank open... hopefully the last key sucked and the new ones will open it. I think it might just be stuck from time not opening it. Any suggestions with a stuck gas cap?

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Old 07-05-2012, 02:17 PM   #22
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From: Muk, WA
Blog Entries: 4

I Ride: fast, except on the road.
Hammer + screwdriver?

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Old 07-05-2012, 02:19 PM   #23
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
“ Quote:
Originally Posted by PeteN95 View Post
Hammer + screwdriver?
Without ruining the tank or lid, I am going to sell or trade the bike to a friend of mine once it is running and moving.

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Old 07-05-2012, 02:21 PM   #24
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Joined: Jan 2008
From: Muk, WA
Blog Entries: 4

I Ride: fast, except on the road.
Lotsa WD40 and hope it's the right key, then. Although, if you pound the screwdriver into the key slot, then force it to turn, it will just break the lock so it will just open with any key or screwdriver. But you won't be able to notice, much, and who would steal gas out of that thing anyway!?

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Last edited by PeteN95; 07-05-2012 at 02:24 PM..
 
Old 07-05-2012, 02:56 PM   #25
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
“ Quote:
Originally Posted by PeteN95 View Post
Lotsa WD40 and hope it's the right key, then. Although, if you pound the screwdriver into the key slot, then force it to turn, it will just break the lock so it will just open with any key or screwdriver. But you won't be able to notice, much, and who would steal gas out of that thing anyway!?
Would PB blaster work instead of WD-40?

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Old 07-05-2012, 03:35 PM   #26
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Joined: May 2011
From: Everett. WA

I Ride: GS1150 Rat bike, NSR(G)500cc two stroke,CBR 900rr,98 Super chicken
The rubber seal has probably welded it's self to the tank.
If the key turns the lock ok but still doesn't open, then it's just stuck.
If the key wont turn it, maybe the PO changed something and you're screwed.
You'll have to pick or brake it like tall dude said.

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Old 07-05-2012, 06:17 PM   #27
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
Projects

No surprise it was stuck closed, it turns out that the latch was stuck to the metal on the inside of the tank causing the key to not turn all the way. Once I got the tank open, all I see in there is disgusting scaling all over the inside.... any suggestions for products to clean it out? Does anybody here have a favorite cleaner?

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Old 07-05-2012, 06:49 PM   #28
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
Electrolysis and a por-15 kit.

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Old 07-05-2012, 06:54 PM   #29
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Joined: Feb 2007
From: Seattle

I Ride: All kinds
That petrol tank is skanky business. Gonna need a kreem job or electrolysis or maybe source another tank altogether. Try this link:

http://www.motorcycleanchor.com/moto..._tankrust.html

A customer recently went though the same process with an '87 Intruder 700. Although this one had just 800 miles and had not run since 1987. For some reason the tank on his was perfect inside go figure. The forks were not useable however and there was surface rust/pitting/corrosion in lots of places. New (used) forks, carb/fuel system rebuild, new tires, fluids, plugs, battery, etc., etc. and he had a fantastic running bike for cheap that actually looks ok.

Some projects are worth the journey hopefully yours is too.

Projects

Projects

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Old 07-05-2012, 10:58 PM   #30
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
“ Quote:
Originally Posted by Red Label Moto View Post
That petrol tank is skanky business. Gonna need a kreem job or electrolysis or maybe source another tank altogether. Try this link:

http://www.motorcycleanchor.com/moto..._tankrust.html

A customer recently went though the same process with an '87 Intruder 700. Although this one had just 800 miles and had not run since 1987. For some reason the tank on his was perfect inside go figure. The forks were not useable however and there was surface rust/pitting/corrosion in lots of places. New (used) forks, carb/fuel system rebuild, new tires, fluids, plugs, battery, etc., etc. and he had a fantastic running bike for cheap that actually looks ok.

Thanks for the link Kai (is that correct?), I am trying another very similar method to one of the methods in the link. I put a 16 oz container of navel jelly (phosophoric acid) in the tank diluted to the top with water. I am going to let that sit for the next day and see where I am tomorrow with the tank.

This was what the gas looked like when I took it out of the tank, which smelled very strongly and very horrible.
Projects

Here was the petcock when I took it out... pretty well covered in varnish that sat so long it turned to a black sludge
Projects

I was actually surprised at how much of what is in the tank is actually scales of rust instead of an actually rusted tank wall. After a couple rinses, the inside of the tank looked a whole lot better, but still horrible. I could at least see good portions of good tank wall, but there was still scales on the side.

I will try to get back tomorrow with an update on how the tank is coming along.

STAY TUNED GUYS!

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Old 07-06-2012, 04:59 AM   #31
Mic
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Joined: May 2007
From: Between Bellevue, Wa and Hood River, Or
Blog Entries: 26

I Ride: a KLR 650, and an XT 225
as has been mentioned, do electrolysis on the tank to remove the rust, and then use POR 15 (not KREEM!) to seal it.

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Old 07-06-2012, 05:45 AM   #32
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Joined: May 2011
From: Everett. WA

I Ride: GS1150 Rat bike, NSR(G)500cc two stroke,CBR 900rr,98 Super chicken
I had a guy bring his 96 CBR 900 for carb work (+ bunch of other things too). He couldn't figure out why it was running bad. Turns out the petcock was bad and this is why>>>>

This is after sloshing a small amount of fuel and filtering it through a paper towel.
Projects

Had so much rust it clogged the out let>>>

Projects

Picked a bunch of crud out of the petcock and finally and to replace the cover set.
Projects

Pics don't do justice to the volume of crap I found.

Guy said he tried to flush it out. For some reason it still ran bad......go figure.
He was also riding with no front brakes. He took out one set of pads (to match up to new ones, never put em back in) and got the plunger stuck in the master cylinder. Something else I had to fix for him.

After all that. I recommended he replace the tank and not try any more DIY work on his bike.

Bad tanks and gummed up carbs can be a real pain in the ass parts.

You say you are selling or trading it away?
Guess that's the end of the project?



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Old 07-06-2012, 09:31 AM   #33
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
“ Quote:
Originally Posted by nsrg500 View Post
I had a guy bring his 96 CBR 900 for carb work (+ bunch of other things too). He couldn't figure out why it was running bad. Turns out the petcock was bad and this is why>>>>

This is after sloshing a small amount of fuel and filtering it through a paper towel.

Picked a bunch of crud out of the petcock and finally and to replace the cover set.

Pics don't do justice to the volume of crap I found.

Guy said he tried to flush it out. For some reason it still ran bad......go figure.
He was also riding with no front brakes. He took out one set of pads (to match up to new ones, never put em back in) and got the plunger stuck in the master cylinder. Something else I had to fix for him.

After all that. I recommended he replace the tank and not try any more DIY work on his bike.

Bad tanks and gummed up carbs can be a real pain in the ass parts.

You say you are selling or trading it away?
Guess that's the end of the project?




The carbs are good, Tank is full of crap like the one in the pics. I am going to trade if for a dirt bike from a friend so my brother and I can go riding together and so my friend has a way to get to work over the summer. It will not be the end of the project just yet. I still need to get it running and moving on its own and all put back together.

I will get a picture of it when it is all put back together for you guys!

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Old 07-06-2012, 11:58 AM   #34
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
Got off of work early today so I decided to play around with the tank. After a few drains and fills with water, something came out of the tank
Here is a picture of it.Projects

The smaller piece to the left is a part of it that I decided to flip over to show you both sides. I think what I thought was rust scales turned out to be an old coating on the inside of the tank.... who would have thought. I am right now repeatedly filling the tank with water and shaking it around with some nuts in there to try to scrape the stuff off. I am going to do this for a while and check back here to see what you guys think.

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Old 07-06-2012, 12:01 PM   #35
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
Looks like an old Kreem or RedCote coating. POR-15 won't do that. Definitely a coating though.

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Old 07-06-2012, 12:45 PM   #36
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Joined: May 2011
From: Everett. WA

I Ride: GS1150 Rat bike, NSR(G)500cc two stroke,CBR 900rr,98 Super chicken

I think I'd be in the market for a replacement.

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Old 07-06-2012, 03:15 PM   #37
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Joined: Jul 2010
From: Kent, WA

I Ride: 2011 Kawi Versys and a 1999 Yamaha WR400F
Got the bike out today and started it up... one problem though, it is idling very high.... and when I give it some gas, it will sometimes pop loudly out of the right pipe as it returns to normal idle, only to return to the fast idle. This is all without choke on too... Ideas?

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Old 07-06-2012, 03:17 PM   #38
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Joined: May 2011
From: LaCenter, WA

I Ride: 2003 Copper SV1K
Carb bowls are full of crap and/or still dirty. It's running lean. Did you vacuum sync them? I see you didn't uncover the A/F mixture screws. If you didn't pull those and clean the carbs, the carbs ain't clean.

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Last edited by RedKat600; 07-06-2012 at 03:19 PM..
 
Old 07-06-2012, 03:26 PM   #39
Shredder
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Joined: May 2011
From: Everett. WA

I Ride: GS1150 Rat bike, NSR(G)500cc two stroke,CBR 900rr,98 Super chicken
Bet it's a pilot jet partly plugged. Letting just enough fuel so that cylinder doesn't go dead. That's why the idle is climbing.

Just guessing.




Waiting to see what happens.

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Old 07-07-2012, 06:00 PM   #40
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Joined: Aug 2010
From: SoKingCo, WA

I Ride: ... here and there
Are you still working the inside of the tank, trying to de-rust? If so, try EvapoRust: http://www.evapo-rust.com/

Nice and safe to work with; does a good job. I got mine at Harbor Freight, but they say you might also find it at Autozone or O'Reilly.

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