New tank.

[Nick]

After all my work cleaning tank with vinegar, filters, pump, etc my first ride out revealed a spot on the paint near the filler cap. Pushed my finger down on it as you do and a lump of paint fell off. Tank has rust pinholes all over the top. Had this bike from new looked after it, its spotless and my pride and joy so as you can imagine I'm a bit gutted. So as it rusted from the inside out my question is can you tell me has anyone got any advice or even if you can run a fuel additive all year round to prevent any rust in the tank and system. New tank arrived today and although the old one lasted 12years I don't want the new one to go the same way. Thanks nick.

[Tony Nitrous]

Don't use E-fuels with Ethanol in them.
Use the bike regularly, fuel splashing around won't let it rust.

I have bikes with 38 year old tanks on them and they are rust free.
I've never had this problem.

[Bielie45]

As Tony said
Never let the tank stand to long not filled up, dont know where you are in the world condensation takes place doesnt matter what fuel when standing long periods, large temp variations controbute to the condensation, full tank = no oxygen above the fuel to create condensation that sits and rusts from the inside.
Diffrent climates play a role too, some areas in the world never have this condition because of very constant temps.

[Nick]

Well I tried to find out if there is any ethanol free petrol out there, think I know less now than I did before. Some of the vintage bike sites recommended BP super unleaded and most recomend the super type but could not find a definite answer. Putolean do an addative that you can use all the time to combat rust and the bad effects of ethanol, could be worth trying.

[Andre]

In my country only 2 Brands carry ethanol-free petrols (Total Exellium Super Plus and Aral Ultimate 102). Most of you can care little about this unless you come and visit.

For GB I found this:
https://www.esso.co.uk/fuels-faqs

What is the ethanol content of your fuels?
The majority of unleaded 95 Octane petrol sold in the UK contains up to 5% ethanol as required under the Government's Renewable Transport Fuels Obligation (RTFO).

There is currently no requirement for renewable fuel (such as ethanol) to be present in super unleaded (97 grade petrol).

Esso super unleaded petrol (Synergy Supreme+ Unleaded 97) is ethanol free (except in Devon, Cornwall, the Teesside area and Scotland). We would therefore advise anyone who has concerns about the presence of ethanol in petrol to use Synergy Supreme+ – providing they do not fill up in Devon or Cornwall, the Teesside area or Scotland.

[MarkN]

For a few years now I've been using an additive by Sta-bil which is a fuel stabiliser for petrol with ethanol in it. I've just looked on the back of the bottle and it says to keep the tank 95% full to avoid condensation. This is probably the same sort of stuff as Putolean.
It's worked so far. I get it off ebay, an 8fl oz bottle treats 20 gallons of fuel

[Andre]

@Nick

The issue with water condensation in the top tank area won't be helped with just ethanol free petrol or fuel stabilizer. Though either one (choice depends on if you can get ethanol-free petrol) will be a good measure.

If the tank rusted at the top from the inside, the only thing that will help there is, as Tony said, to ride it frequently. Also, when not riding for a while, fill her up to the rim (24-liter mod or slow trickle) and take the bike of the stand regularly and move it by hand a bit so the fuel will splash around. That will move water that may have condensated by flushing it away from the top area.

If storing it during winter you can take the tank off and store it together with the battery in a heated room.

[Mick_J]

Well I tried to find out if there is any ethanol free petrol out there, think I know less now than I did before. Some of the vintage bike sites recommended BP super unleaded and most recomend the super type but could not find a definite answer. Putolean do an addative that you can use all the time to combat rust and the bad effects of ethanol, could be worth trying.

The only ethanol free fuel in the UK is Esso super unleaded, everything else has at least 5% in it but I think that even Esso has 5% ethanol it in Cornwall and Teeside.

[Teufel]

https://www.kbs-coatings.com.au/product/auto-fuel-tank-sealer-kit/

I have used this on a couple of tanks. It just eliminates the problem.
Seal it - forget it.

[grog]

my mates 2003 model rusted tank at bottom. got stuck on way moto gp at phillip island. petrol just poured out from bottom area. 120 th ks, always used premium. new tank cost him 2 days and 1300 bucks. wasnt unusual for him to refill everyday so no idea why it happened. he always filled to brim, injector cleaner/ water inhibitor every month. he averaged 20 th ks a year on that bike so no stale fuel. a big rock on roundabout fixed it, written off. his new Busa lasted 6 months, also written off under 10 th ks. now has a 14 Kawa, no probs for years.

[Notty]

When I took my tank out to be resprayed it was quite rusty underneath so I used Black Hammerite as I wasn't paying for a can of white as no-one will know except me, oh and now you lot - bugger ! anyway. Most parts are easy to get except model specific such as generator covers etc (got new ones just in case ) and of course the tank. Are new K5/6 tanks available ? looked on some sites but not sure of the code...a new K4 and K7 on Ebay for around £680... but don't you have to get the transfer sets as well? ...will definitely put a new tank on my Christmas list !!  Mrs Notty won't know as father Christmas has a client confidentiality claus !! 

[KiwiCol]

Notty, instead of buying bits you may need one day, why not just buy a 2nd bike?  Just leave it there & use bits as required, be way cheaper than buying new parts & leaving them sitting around.

[Notty]

Notty, instead of buying bits you may need one day, why not just buy a 2nd bike?  Just leave it there & use bits as required, be way cheaper than buying new parts & leaving them sitting around.

Mrs Notty may notice 2 in the garage Col !! but she won't find bits spread around !! 

[KiwiCol]

Ya don't have to tell her it's yours, just say you're minding it for a mate off here.  They could be away a while, & then 'gift' it to you as they're not coming back to UK.   Sorted.

[ajl]

i just had to replace my fuel tank  at 7500 miles on a 03 k3 !!!!! it will be coming off  next month  emptied and dried out .then i will mix a little oil with fuel and swill it around ,leaving it until spring .. i conclude ,suzuki make fuel tanks out of shite steel ...