My Honda Shadow gas tank is rusted (what can I do?)

“Has anyone successfully dealt with rust in their Honda Shadow gas tank? I’m tackling this head-on and could use some pointers!”

Response

I’ve grappled with tank rust on my own ride. After some digging and elbow grease, I discovered multiple ways to banish rust. One standout solution that worked for me was using electrolysis.

Solutions that worked for users

Solution	Users Who Found Success	Approx. Cost USD	Time Needed (Minutes)
Electrolysis	2	$30	1440
Vinegar Soak	3	$5	7200
Professional Cleaning	2	$100	60
Naval Jelly	1	$20	1560

Symptoms

• Visible rust inside the tank
• Clogged fuel filters and petcocks
• Flakes of rust in the fuel

Possible Causes

• Moisture accumulation
• Ethanol in fuel attracting water
• Lack of protective coating inside the tank

Solutions

1. Electrolysis

• Steps:
  1. Gather a battery charger, baking soda, and sacrificial anode.
  2. Mix baking soda with water to create an electrolyte solution and fill the tank.
  3. Connect the anode to the positive lead and place it in the tank without touching the sides.
  4. Attach the negative lead to the tank itself.
  5. Turn on the charger and let the process run for 24 hours, checking periodically.
• Expert Tip: Ensure the setup is outdoors or in a well-ventilated area to avoid any gas build-up.

2. Vinegar Soak

• Steps:
  1. Fill the gas tank completely with white vinegar.
  2. Allow the tank to sit for several days, shaking it occasionally to dislodge rust.
  3. After soaking, discard the vinegar and rinse the tank with water.
  4. To remove residual moisture, follow up with a drying agent or leave it to air dry.
• Expert Tip: Vinegar is acidic but gentle; however, it might take longer to see results compared to harsher chemicals.

3. Professional Cleaning

• Steps:
  1. Remove the gas tank from your motorcycle.
  2. Take the tank to a radiator repair shop for professional cleaning.
  3. Allow the professionals to boil out the tank and perform any necessary leak tests.
  4. Repaint the tank if necessary after the cleaning process.
• Expert Tip: This is the most hands-off approach but can be costlier than DIY methods.

4. Naval Jelly

• Steps:
  1. Apply naval jelly liberally inside the tank.
  2. Fill the tank with water and let it soak for 24 hours.
  3. Drain and rinse the tank, then repeat the process for 8 hours with a new application.
  4. Use oil and nuts as agitators to dislodge stubborn rust.
  5. Rinse with acetone and dry the tank before applying a sealant.
• Expert Tip: Naval jelly is potent against rust but requires careful handling and proper disposal.

Motorcycle Models Where This Worked

• Honda Shadow VT1100C 1987
• Honda Goldwing Aspencade 1984
• Honda Shadow CM450 1983