Rusty Fuel tank - How to fix? , and what fuel filters work?

The best prevention, always park the bike with as much fuel in it as possible. The bike heats up, the engine is below the tank and heat rises. The fuel gets hot, then when you park it.... Condensation happens.

As for cleaning the tank. I'd buy a tank coating kit and follow the destructions.

Just about any fuel filter for almost any bike should work. Could probablly pick one up at an Auto Parts store for little $.

Fuel line, I'd use some sort of fire resistant coated rubber hose similar to what comes from the factory. Again, parts store.

 

one of the best procedures I have ever used for trating a tank goes like this:
1) Get a strip of mild steel anout 60cmx1cm and rub a magnet in ONE direction so it magnetises (I think I spelt that right)
2) cut it up into 2cm chunks
3) drain and remove the tank...dismentle all the attachements and hoses and caps etc... slash some metho in it and let it dry in a dry ventlated area...
4) buy a MARINE paint primer...
5) buy now the tank should be dry (as finding a cheep primer took you a day or so) so drop in the metal bits and shake (ware protective gear on your ears!!)
6) take out all the metal bits.. if you have an air compressor blow the dust out... if not shake it it out...
7) was the inside of the tank with metho again and again till it runs out clean... let it dry...
8) plug all holes ecept for the smalest one...
9) pur the primer in... shake shake shake... pour it out...
10) let it dry (usualy 24 hours)
11) now you can store sea water in the tank and not wary about rust <!-- s --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s -->


The special tank tratments you buy at the store use a marine primer as a coating and cost around $80 if you put together a kit yourself you will have enough to do about 5 or more tanks... and it will cost you less than one store bought kit <!-- s --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s -->

 

I'm pretty sure i've got the same problem, however i've been a bit lazy and followed the ostrich approach (head in the sand) - ie. if i can't see the rust in the tank, then it can't be there. So i don;t look for it. (This is not advice, by the way.) When i get some time i will try a scaled-down version of t-bone's method.
I don't run the bike with the tank near empty, because that's when the concetration of rust/crud will be at its highest.
You should be able to get an air filter from any official yamaha parts store (just tell them the bike model/year) but beware, you will PAY for it. Expect around $80 (its a canister with a paper element, and you have to buy the whole thing, can't replace just the element - but you can clean it with compressed air if its not too rooted).
Oh and welcome to the site, man. <!-- s:lol: --><img src="{SMILIES_PATH}/icon_lol.gif" alt=":lol:" title="Laughing" /><!-- s:lol: -->

 

for air filter try doing what Koma did... lol $12 later... and he has a new filter... dut his bike is running rich now... so my thoughts are it needs a bit more tweeking...

 

We did put more foam in than we thought was necessary... so i'll pop the tank off and have a look how it's going. Will remove one of the layers and see if it sorts it all out. <!-- s --><img src="{SMILIES_PATH}/icon_smile.gif" alt="" title="Smile" /><!-- s -->

For everyones information it's a few layers of open cell 'spider-foam' or so i've heard it called before. I'll post up a few pics from the conversion next time im in a write-up kinda mood.

 

an even easier method is to drain the tank,mix up a batch of epoxy resin, **** it in and leave overnight-well it worked for me!!!!

 

get in the mood mate! I'm due for a filter replacement and don't really wanna shell out another $85. SOunds like a good solution you came up with. Would like to see how you did it. Where do you get this "spider-foam" from?

 

None other than Clarks Foam & Rubber.
Supposedly a guy ordered a sample from one of the big airfilter manufacturers, and took it into Clarks to get them to match it. They said 'yeah no problem, i'll get you in a heap of the stuff' and spent about $50 or so - he ended up with so much he'd never have to buy another filter again!

If i recall, i think it was one of TBone's mates.
I only got some photo's on my phone... but their good enough to demonstrate how it was done. Still ironing out the air flow guesstimate though, i think it may have one layer of foam too much. It was running perfectly for about a week then started to richen up a bit - i'll pull out one of the layers of foam and see if it sorts it out.

Either way, i think it's got 3 layers of 12mm foam in there and compressing it down a bit - so taking it back to 2 layers with no compression will probably free things up quite a bit (possibly too much!).