Vulcan 1600 Classic - Leaky Gas Tank, Part 1

Well crap! I found my gas tank has developed a small leak. After a little research online, I think I can fix it. But wait! I just met a new friend this past year that could help me out.

[@dustinpederson2531]

Hello, new the channel. I have the same bike mine is a 2006. I Actually used your video on oil change to do mine, it was a very nice guide so thank you. When doing my oil I discovered that I had a gas leak. I was thinking it was a fuel line but couldn't find the source. After looking up information I found another one of your videos. Looking at my tank it looks like I might have a leak in the same spot you do. I haven't taken the tank all the way yet but it really looks like it coming from that tab. right around those bolts are the first place to get gas on them. So I subscribe today and can't wait for next video to see what happens. Until then I'm a look at a couple more your videos and see what else I can do for a tune-up. Thank you again

[@ChefHikerBiker]

Glad to have you here. The leaky tank has been quite a project. I think I had it done, then something else goes wrong.

[@dustinpederson2531]

I'm going to try using J-B weld and seeing if that fixes it

[@ChefHikerBiker]

Good luck with that. I used stuff that said it was resistant to gas, and it failed on me.

[@58gennaro]

Thanks. Taking my tank off to paint. You made it seem easy.

[@ChefHikerBiker]

Thank you. Glad you found it helpful. Thanks for watching!

[@nursekelly2834]

Hey ik I’m late but that’s a very common issue with the 1600’s mine did the same thing. But mine was leaking around the tabs, my mechanic at the time who worked for a licensed Kawasaki dealer. Reported it and Kawasaki issued me a brand new tank. This was in 2019. Mine is an 06 VN1600

[@ChefHikerBiker]

Yeah, I probably should have taken it to a licensed Kawi shop. When I talked to Kawi myself, they said they couldn't do anything, because the recall was only on the 2003 models.

[@gottashredd]

I called the and they said it's not covered either

[@daltonvickersjr9441]

I will have to check that tab area on my 2006 1600. Thanks for the videos.

[@ChefHikerBiker]

it's a very common problem. And the main thing is, it's deep inside. The outer edge might look fine, but the inside (between the two metals) is where the rust will be.

[@daltonvickersjr9441]

@@ChefHikerBiker Thanks Marc. I am going to check mine out. Who did you order your Grasshopper backrest from? I want to put one on mine

[@daltonvickersjr9441]

I found the grasshopper site and ordered one for mine. Thank you

[@ChefHikerBiker]

Awesome! I love mine.

[@pete2109]

Hey Marc sorry about your problem with the tank, it will be interesting to know the outcome as I’ve got the same bike. My main fuel line came off while riding couple of months back, talk about scary! 😱😱😱 Was down to the guy who had the bike resprayed and coated the fuel tap under the tank, and just pushed the connector as far as he could on soft paint but didn’t listen for the “click” when you put them connectors back on!!!! 🤬🤬🤬🤬🤬😡 One little thing Marc any chance of looking at the lens of the camera instead of to the side? 🥴😂😂 Thanks again mate 👍🤘🤘

[@ChefHikerBiker]

I bet that was scary, All of a sudden having gas pour all over you and a hot engine. Although I'm trying to figure out why they painted the fuel line. Thanks for the tip on looking at the lens. I am trying to get better. I just always want to see what I'm shooting.

[@pete2109]

Marc VanderPal The previous owner had the whole bike resprayed bodywork and frame, when he sprayed the tank he should’ve masked the fuel line off but he didn’t and sprayed the metal feed pipe 🤬🤬🤬🤬 With the paint on there it made it thicker to push on and he only got it a little way on and not all the way so it clicks into place 😡 And yes it was scary petrol was gushing all down my leg it was handy there was a service road 50 yards away! 🥴 I put it back on with a bungy cord till I got home then found the fault took all the paint off and the pipe connected properly 👌👍

[@ChefHikerBiker]

I'm glad you weren't hurt and that you got the fuel line on properly.

[@williespoonemore3392]

Yep my 1600 customs leaking . Took it to shop they said it was under warranty but they looked for tank and couldn't find one so , so they didn't bother to fix it and decided beings they couldn't find one the warranty was void even though it was a recall wth , really ticked me off !

[@ChefHikerBiker]

When I talked with Kawasaki themselves, they told me the recall was only for the 2003 model year.

[@williespoonemore3392]

I know it was for 03 , they should have tanks 😔

[@ChefHikerBiker]

Well, it hasn't been in production for 15 years. They're not going to keep making parts and stuff for it.

[@williespoonemore3392]

Ya there suppose to honor till it hits the bone yard but ya custom 03 1600 😠

[@donellophillips8417]

Get yourself a kerosene heater for your garage they work well

[@ChefHikerBiker]

Maybe someday. I might want to insulate the garage first, that way all the heat doesn't just pass through the siding and shingles.

[@tomgould2410]

There is a lady who demonstrates how to pick up a big bike. Works well. But, then she tells how to pick a big bike off the stand if you are a smallish person by grabbing the bottom of the left side of the tank. Well, I am not small but decided to see if her method of picking the bike off the stand was easier. It wasn't. But, then the leak started. That is how I found your three videos re: gas tank leak. My bike is a 2008 Classic. An absolute wonderful bike; the best of my four bike collection !! (My wife is the best !!). QUESTION -- after all you went through, would you have preferred to buy a used tank from eBay instead of going through the fabrication, etc. problems?

[@ChefHikerBiker]

My troubles were kinda self inflicted. If we had done a pressure test after the first welding, we could have found the leaks and fixed them tight away and wouldn't have had to do the painting twice. The other issue was do to a bad batch of red tank seal. But, that will be explained in part 4. So, yes, if I had to do it all over, I would do the repair again.

[@tomgould2410]

I decided to use POR15. Gulp.... From the KZbin videos and comments, if applied properly, it should do the job.

[@bazilo134you]

Hey Marc i have a Meanstreak 06 very similar to your bike and i´ve been having trouble in high speed when the bike is getting close to 100 mph the bike starts to cut out almost like pulling me back real hard repeatedly and the tacometer just won´t pass the 5000 rpm mark sometimes above 4000 rpm just keeps getting back, ive seen videos of meansteaks and they without problems take it above 5000 rpm to 120 mph. Do you have any idea of what could be; the gas pump is clean, new spark plugs, the air filter is ok, inyector recently clean.

[@ChefHikerBiker]

Sorry, I'm not a mechanic to know exactly what's going on. My guess is that it might nit be getting enough air. But that's just a guess.

[@ShaderQ]

Hey - I got the same bike. Always having a blast riding it ;) Recently it seems that the pressure in the gas tank won’t release, or won’t regulate itself, after riding for about 15 minutes. When I shut the bike off there is still a somehow loud noise coming out of the closed gas cap. When I open it, it’s blowing air out really quickly with a „bang“ like a loud „PFFFFFF“ Do you know what the issue with this could be ? Please excuse my bad English, I’m from Germany, and it’s not my mother tongue

[@ChefHikerBiker]

Your english is very good. Better than most people over here. Haha I know the gas cap has a vent, maybe yours are clogged up.

[@theone2be33]

Should've used Steel Stik instead of JB Weld

[@ChefHikerBiker]

I still would have the thought of it being a band aid fix. Glad to have the tank properly welded.