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Hi Paso folkes, Im new at this(first post), my 907 has a very small petrol leak from rear of tank seam near moumting bracket, has anybody with similar bike had the same problem? it is not actually leaking petrol but but has petrol residue and the paint behind the seat has started to peel off the size of 5cm, any advise would be appreciated.
Claude

I have had issues on every Paso tank at one time or another.
Some I have welded up some I have used the POR sealant kit.
The nice thing about the POR kit is it is easy and you won't have to fix your paint. Welding needs to be done by some one with a clue as it can very very dangerous when not done with the proper precautions. Very small leaks can sometimes be patched with fiberglass as well but I prefer the POR kit,when done properly it will last for years.

Welcome on board.
I had the same issue on my old 906 and fixed it with a "normal" welding.
Actually, I had to paint the welding (and the surrounding zone) to avoid any rust.
Ciao

thanks for your reply, I wouldnt like to weld the tank, but that POR kit sounds interesting, higgy could you elaborate, is it some sort of petrol resistant resin, once the tank is empty and dry, can the leak be fixed internally?(pressed metal seam)

http://www.por15.com/CYCLE-TANK-REPAIR- ... info/CTRK/

You can find out all about it here.runs 40USD

And the new Heavy Duty kit is here for 45usd
http://www.por15.com/HD-CYCLE-TANK-REPA ... fo/HDCTRK/

The instructions for both kits can be downloaded as well
I have used quite a few of POR-15's products and when you follow the directions they all work extremely well

thanks for the info higgy, greatly appreciated, I've owned my 907 since new and your slogan "making mechanics out of riders" is very appropiate, although my bike has never let me down, they are a high maintenance machine, thanks again

Your are most welcome
I prefer to think of them as a tinkerers delight

higgy wrote:Your are most welcome
I prefer to think of them as a tinkerers delight

sheeit Higgy , thats a spin and a half
My tank also leaked / cracked at the front mount .I cut front mount off and welded on a 1/8 " patch and re fitted the mount .
tinkers delight .....ha ha ha yeah whatever

just to update this post, I'm wrapped ,found out there is a POR distributor just down the road from me and picked up the fuel tank repair kit, 72 aussie $$, and if you follow instructions it will last a very long time, the coating goes inside the tank so no need to remove paint
another thing...anybody restoring old bikes should have a look at the POR 15 products a good contribution from the US of A.

POR rocks the restoration of any vehicle I use the chassis black for stone chips on radiators,levers, frame anything black. Do the prep and its is as easy as it gets and rock hard.

Used POR15 in my tank it did a great job

One thing that occurs to me is that using tank sealant may only mask an underlying problem. I had a problem with the front mount and it was fixed with a plate. It may be that if your front mount is cracked it may be putting pressure on the rear mount.

Mike

Almost every tank will leak eventually. removing the front mount and adding a support plate is a good solution. POR won't stop the cracking. The best way would be to modify the front mount by shortening the tube to rest on the rubber mount rather than capture it. this will of course put extra strain on your wellnuts and thru holes in your precious body panels.
I'm sure if we put our collective minds to a solution we can come up with a goodie.
Me,its been a long week and I am going to sleep for at least 12 hours..............................

I had a good look at the tank, it all looked good, the front mount looked good as well, the weld holding the front mount together is a bit minimalistic and can understand why they do fail, so to strengthen it I removed the paint with a wirewheel (turn tank upsidedown) and applied TEROKAL-5045 a two part metal bonder around front mount and base of tank, I also did bottom rear mount as well, its easy to work with and takes 2 days to set, but once it does it goes very hard, I strongly recommend it not cheap

I used to own a Suzuki. The front mounting on the tank had two C shaped lugs that located onto large rubber mounts on either side of the frame, just behind the steering head. This solution offers more support and spreads the load. The rear mounts stop the tank from moving. I think it would not be too difficult to modify the Paso. Mind you, I opted for the easy solution and had the new plate welded on the underneath of the tank. The welder who carried out the mod also ground the mounting lug down before he welded the plate on, so the tank fitted correcly.

Mike