- 1). Remove all the gas from the tank. This can usually be done by shutting off the gas at the petcock below the tank, removing the fuel line, then attaching another line or piece of hose to the valve, opening the petcock and draining the gas into an approved gas container.
- 2). Remove the gas tank. There may still be some gas left in the tank, so be careful. Depending on the motorcycle, this can be as simple as taking out a single bolt found near the base of the tank, next to the front of the seat. A good repair manual specific to your bike can show you how.
- 3). Remove the fuel petcock and any inside filters from the tank. Also remove the fuel sender, if any, and any other valves from the tank. Refer to the repair manual specific to your bike for more information. Be sure to check these parts for bits of rust and clean them as needed.
- 4). Rinse the tank with water to remove any remaining gas. Be sure to dispose of the fluids properly--don't allow gas or contaminated water to spill on the ground.
- 5). Close up the bottom of the tank with duct tape or even an old rag. Add about 1 qt of distilled water and about the same amount of pure sand (usually available at auto parts stores). Close the gas cap. Shake and rotate the tank vigorously. This is the time consuming part--it can take 15 minutes or more.
- 6). Drain the tank and check the interior. If you still see rust, repeat Step 5 as necessary, and instead of using sand, you can also try BBs or a small amount of clean gravel. If you don't see rust, rinse the tank repeatedly with the garden hose, then with distilled water. You must ensure there are no abrasives left in the tank. Then carefully rinse the tank with gasoline to remove any traces of water, which would just cause the tank to rust again. Remember to dispose of all fluids properly. Contact your local auto parts store to see if they have a recycling or disposal program.
- 7). Reinstall the petcock and any other parts--using a new fuel filter--and reinstall the tank.
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