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Thread: Suzuki GD-110 (2013 model) fuel tank completely rusted from inside! Help requested!

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    Default Suzuki GD-110 (2013 model) fuel tank completely rusted from inside! Help requested!

    Assalamo Alikum everyone! I am Ali Abbas from Lahore & have been a silent reader of topics & threads on this forum since over a year. However now, since I have seen the GURUS here being so helpful in guiding others car/bike/travel related issues, I am submitting my question.

    I bought a Suzuki GD 110 in June 2013. Have driven it 17,000 K.M. till date. Since past 03 months I have been facing this problem. In September 2015, the bike refused to start up while running. Took it to Suzuki mechanic who (after thoroughly expecting) said that?the tank has been rusted to SUCH an extent that?.. you need to replace it! (the rusty mixture was clogging the fuel filter and carby, which is what made the bike stop)

    New tank of GD-110 costs PKRs. 8,000/= so I decided to find a way around that. Finally showed it to a professional who cleaned it up (through that NUT & BOLT & KEROSENE OIL inside & shake violently & then rinse & repeat method). Most of the rust was cleaned dup.
    However this still has not fully solved the problem as rusty mixture clogs the fuel filter and bike stops running.. sometimes. Guys, my daily travel is a lot? I really need my ride to be reliable?..

    I really need guidance from you experts to solve this issue, either suggest a method or kindly point me to someone (in Lahore) who professionally cleans bike tank rust. Replacing the tank is an expensive option which at this point in time I am not willing to consider.

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    You can get the tank painted from inside

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    http://www.aliqadri.com

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    It is really a nightmare for a so called imported bike. I cant believe this. Pity on Pak suzuki.

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    Best but busted way unfortunately is replaced with a new tank


    Wail hai, Be namazion k liye ..

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    Alright, no positive replies it seems (exception of the fellow who gave me link to that website, I did check that out earlier). Anyway, I am going to share with you folks progress I have made on the matter, in order to help those who ever face similar problem

    *immediately scroll down at the bottom of this post in order to have whereabouts of the professional who does it in Lahore for PKrs. 400. If you just want to have it done that way.

    Methods used around the world, their precautions & efficacy: -

    Motorcycle gas tank rusting is a common issue. But like I said, if it is left untreated it could make your ride un-reliable, you can read what I had to go through in my first post. Anyway, I have seen several videos & read many articles over the past couple of weeks on the matter, which I am going to narrate hereunder for everyone’s knowledge:-

    1) Muriatic acid method : -

    Muriatic Acid is WEAK FORM of HCL (that’s it really) . Kindly go to youtube (on your android phone, the app works) and view the 10 min video of the method being applied. HOWEVER it DOES require some precautions, proper covering of hands/eyes & not to inhale the fumes and doing it in open air. The entire process could take up to two hours and would comprise of

    a. Disassemble the gas tank, empty it completely

    b. Use the Muriatic Acid method as shown in video, leave it in for some time (again, as per video)

    c. Rinse it out & clean. Neutralize the acid (baking powder solution) Wash, clean & dry the tank

    d. Fill it up with gas & it should be good to go

    Another article I read was a guy using 01 part Muriatic Acid and 07 parts water solution & leaving it in tank for around 15 hours. That worked wonders also

    2) Electrolysis method.

    Ok, I assure you folks, this is THE BEST way of de-rusting a gas tank or pretty much any rusted iron/steel equipment. THE BEST! Because, the metal would not be harmed in ANY WAY! (whereas the acid will have its toll on the inside of the tank- steel)

    What is required?

    Empty rusted gas tank (dis-assembled)
    Get a battery charger
    Sacrificial anode (made or IRON only) toota hoa SARYA will do
    Electrolyte solution
    And make sure light aa ahi ho 

    The aforementioned are the raw materials of the process. I have not practically done this as I had to get my gas tank cleaned on emergency basis (the rusty mixture was getting to flow into carby pretty often leaving me… dragging the bike on the road :-/)

    The guy who does this, my opinion of his work & recommendation:-

    The dude’s name is Ejaz & he has his setup 03 or 04 shops to the LEFT side of Momin Pura graveyard (while facing towards the graveyard) on Mcleod Road. He professionally cleans/welds rusted/leaking gas tanks of bikes/rickshaws etc.

    He used the HCL method. The entire process was conducted in front of me and eventually an extreme amount of rust/gunk got out. I found his services quality to be fine. The time he took was around 45 minutes which included Acid bath, Acid neutralization, leaving of mild acid inside the tank for some time, rinsing it all out, washing cleaning & finally rinsing with petrol.

    I am personally going to collect equipment for Electrolysis method at home for personal interest. Will share my findings with you guys once I have practically tried it and from there onwards, will my services for free!  Cheers!

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