Gas Tank Rust Problem & Good manual

[mataleao]

To wise ones,

I am in the process of reviving this project bike that I bought to practice bike repair - Kawasaki Ninja 750R (ZX750F) 1989. Now the next assignment is my gas tank has rust problem that I have to deal with.

There are many method of cleaning the gas tank but what was your favorite method and simple way to clean the gas tank rust?

I already ordered a Kreem rust removal kit. I also have a bottle of Navel Jelly on my shelf. My wife prohibit me from using her dryer (water and sand shake method).


Also looking for a good service manual and parts manual but only decent manual I could find was
this unknown manual -- Kawasaki Ninja ZX600, ZX750R Repair Manual 1985-1997 for $24.46 from themotorbookstore.com.

If you know any good manual or good source for the service manual, please let me know. Clymer didn't have manual for this model. Haynes manual was for newer Ninja and the illustration was not accurate.

Before I start taking carburetor apart, I want to have at least one manual on hand.

Thanks.

[Bike_Poseur]

I just cleaned the rust out of my tank a couple of weeks ago. I took the advice of someone who has cleaned out a lot of rusty tanks, avoiding a lining kit altogether.

I bought one gallon of muriatic acid (hardware store like ACE). Bought one can of acetone. Bought a base (baking soda).

Fill half your tank with hot water. Add half gallon of acid. Fill rest of tank with hot water. Let tank sit for at least a few hours (It took my tank 4 hours). You can see the rust lifting away. Drain tank into large container. Rinse inside of tank with a water/baking soda mixture. Rinse well with a garden hose.

To dry the tank, you don't need a hair dryer. Just pour a bunch of acetone in there and swish it around. Drain. Give the tank a couple minutes for the remaining acetone to evaporate. Then pour some motor oil and gasoline in the tank, swish it around real good (the oil will prevent flash-rusting), drain, then put new gas in the tank.

You're done. The lining isn't necessary and could even cause you problems later. My tank looks great, nothing but silver metal inside.

But you've already bought the kit so you're probably going to use it. So I hope this is helpful for some other poor sap who wants to clean out his rusty tank.

[Bike_Poseur]

Also one note: disposing of the spent acid was a problem for me. I had a giant barrel full of acid, and I needed to neutralize it to make it safe for dumping down the drain. I put in a few ounces of soda. Still fizzing. Put in a few more, still fizzing. Put in one pound of baking soda. Still fizzing.

Eventually I had poured EIGHT pounds of baking soda into the acid, and it was not neutralized. Some guy at a hardwared store suggested other bases to use: Bleach or drano. Neither bleach nor drano had any effect on the acid. I created a monster.

I waited a day and tried more baking soda, and there was no fizzing. I guess I don't have any advice for anyone who wants to neutralize 5 gallons of acid. Hopefully they will have 50-60 pounds of baking soda on hand.

The carbs: you don't need a manual to take the carbs apart. When you get them open, it is very self-explanatory.