Hey guys, so a few weeks back I purchased my girlfriends 05' Ninja 250 which was mint, had 1600 miles on it
and not a single scratch. The previous owner informed me that the bike was sitting for many years and that
the only draw back to the almost new condition motorcycle was a rusty tank and some dirty carbs. I personally
don't like messing with carbs so I had my mechanic clean them and tune it up (fresh fluids etc.) The bike idled
perfectly and ran fine. I knew the tank rust thing was a big issue but I was too busy bouncing off the rev
limiter and grinning like the first time I rode a two wheeled vehicle.
![Image]()
After teaching my girlfriend how to ride for the second weekend, while heading home, the bike began sputtering
and losing power while we were in the middle of the Manhattan Bridge! I quickly pulled over and saw all the
rust flakes in the clear fuel filter...oh crap. So I flicked the fuel line and filter several times and fuel
started flowing again and the bike started up, but very rough. We eventually made it back after breaking down
a few times.
![Image]()
And then the conquest began. After reading about electrolysis, Kreem, POR-15, Evapo Rust, Vinegar, Bathroom
Toilet Bowl cleaner and a whole bunch of other homemade cocktails it was clear to me that due to the limited
space available in NYC and being indoors during winter, I had to keep things simple. NO ONE on the net had a
HOW TO on this, just simple information and a good luck comments. So the conquest began to do this right the
FIRST time and not have to worry about it again. I also wanted to help others in the community so I documented
the process.
I chose to go with the below:
1. EVAPO RUST (1.5 gallons) - $40
2. Two pieces of a 6 inch steel chain -$2
3. POR-15 Gas Tank Repair Kit - $50
4. My roommates beach bucket - Free
5. Old undershirt - Free
6. Painters tape - Free (I had it laying around)
7. Dishwashing gloves - $2
8. Duct Tape - Free (Had some left)
9. Cling Wrap - Free (found in cupboard)
10. Funnel - $2
11. Red Gasoline jug - Free (owned it)
12. Toilet Bowl flapper - $4
13. Hair dryer - Free - I somehow had one (GF)
Total Cost: $100
Why did I go with EVAPO RUST & POR-15? Because I wanted to try them both out and going the extra mile only hurts
my wallet, but I know its done right which in the end is piece of mind.
So to begin, I took the tank off the bike, emptied the remaining gas into the bucket and began taking the petcock off.
![Image]()
![Image]()
You can clearly see the rust flakes in the fuel filter
![Image]()
![Image]()
Now let's look inside the tank
![Image]()
![Image]()
The pictures dont do it justice
![Image]()
![Image]()
![Image]()
![Image]()
So I bought this toilet bowl flapper to seal the gas tank hole, but it was not perfect, not snug enough to hold
the gas from falling out, definitely buy a bathroom tub rubber nub instead
![Image]()
![Image]()
![Image]()
Now time to tape everything up
![Image]()
![Image]()
![Image]()
Taped up the tank so I dont scratch it
![Image]()
All the EVAPO RUST available in the NYC area
![Image]()
Time to start pouring
![Image]()
![Image]()
Dropping the chains in so I can shake the rust off the tank walls
![Image]()
Finished taping
![Image]()
Now its time to shake it like a polaroid picture! (For 20 minutes anyway)
![Image]()
Drink my roommates beer
![Image]()
I then left the tank for about 3 hours on each side, and then overnight on the top side.
I went to work the next morning and left it on the bottom side, then when I
came back that evening, I decided to empty it out.
![Image]()
I used an old undershirt as a filter, because I wanted to pour the EVAPO RUST back in the tank
in case it didnt do its job.
![Image]()
Look at how disgusting that bucket is! After rinsing with water, all that rusty crap particles
came out.
![Image]()
Not bad looking in there, but the flast rust happens very quickly
![Image]()
The EVAPO RUST that pooled on top of the gas tank hole, ate the paint on the inside part, which
I eventually painted over with the POR-15 tank coverage stuff (which matched), but thats later.
![Image]()
Looking much better in there, all the rust was gone, but some parts looked green in there (which is ok)
![Image]()
![Image]()
and not a single scratch. The previous owner informed me that the bike was sitting for many years and that
the only draw back to the almost new condition motorcycle was a rusty tank and some dirty carbs. I personally
don't like messing with carbs so I had my mechanic clean them and tune it up (fresh fluids etc.) The bike idled
perfectly and ran fine. I knew the tank rust thing was a big issue but I was too busy bouncing off the rev
limiter and grinning like the first time I rode a two wheeled vehicle.
After teaching my girlfriend how to ride for the second weekend, while heading home, the bike began sputtering
and losing power while we were in the middle of the Manhattan Bridge! I quickly pulled over and saw all the
rust flakes in the clear fuel filter...oh crap. So I flicked the fuel line and filter several times and fuel
started flowing again and the bike started up, but very rough. We eventually made it back after breaking down
a few times.
And then the conquest began. After reading about electrolysis, Kreem, POR-15, Evapo Rust, Vinegar, Bathroom
Toilet Bowl cleaner and a whole bunch of other homemade cocktails it was clear to me that due to the limited
space available in NYC and being indoors during winter, I had to keep things simple. NO ONE on the net had a
HOW TO on this, just simple information and a good luck comments. So the conquest began to do this right the
FIRST time and not have to worry about it again. I also wanted to help others in the community so I documented
the process.
I chose to go with the below:
1. EVAPO RUST (1.5 gallons) - $40
2. Two pieces of a 6 inch steel chain -$2
3. POR-15 Gas Tank Repair Kit - $50
4. My roommates beach bucket - Free
5. Old undershirt - Free
6. Painters tape - Free (I had it laying around)
7. Dishwashing gloves - $2
8. Duct Tape - Free (Had some left)
9. Cling Wrap - Free (found in cupboard)
10. Funnel - $2
11. Red Gasoline jug - Free (owned it)
12. Toilet Bowl flapper - $4
13. Hair dryer - Free - I somehow had one (GF)
Total Cost: $100
Why did I go with EVAPO RUST & POR-15? Because I wanted to try them both out and going the extra mile only hurts
my wallet, but I know its done right which in the end is piece of mind.
So to begin, I took the tank off the bike, emptied the remaining gas into the bucket and began taking the petcock off.
You can clearly see the rust flakes in the fuel filter
Now let's look inside the tank
The pictures dont do it justice
So I bought this toilet bowl flapper to seal the gas tank hole, but it was not perfect, not snug enough to hold
the gas from falling out, definitely buy a bathroom tub rubber nub instead
Now time to tape everything up
Taped up the tank so I dont scratch it
All the EVAPO RUST available in the NYC area
Time to start pouring
Dropping the chains in so I can shake the rust off the tank walls
Finished taping
Now its time to shake it like a polaroid picture! (For 20 minutes anyway)
Drink my roommates beer
I then left the tank for about 3 hours on each side, and then overnight on the top side.
I went to work the next morning and left it on the bottom side, then when I
came back that evening, I decided to empty it out.
I used an old undershirt as a filter, because I wanted to pour the EVAPO RUST back in the tank
in case it didnt do its job.
Look at how disgusting that bucket is! After rinsing with water, all that rusty crap particles
came out.
Not bad looking in there, but the flast rust happens very quickly
The EVAPO RUST that pooled on top of the gas tank hole, ate the paint on the inside part, which
I eventually painted over with the POR-15 tank coverage stuff (which matched), but thats later.
Looking much better in there, all the rust was gone, but some parts looked green in there (which is ok)
Thanks much Dom.
