Rebel 250 Fuel Tank Pin Holes - Honda Rebel Forum
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post #1 of 47 Old 07-18-2019, 03:50 PM Thread Starter
 
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Hey guys, I just got my wife's Rebel 250 home,I knew there was rust in the tank, but now I'm seeing leakage from 5 pin holes. I was thinking about using the Caswell two-part epoxy treatment, but one hole is actually a stream the hole is somewhere around 1/32" (+/-) in size. Wanted to ask if the Caswell would work for something that big? Thanks!

'09 Rebel 250
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post #2 of 47 Old 07-18-2019, 05:15 PM
 
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yes it sure will
tape outside of hole, use 1/2 of pint kit...
Caswell is Very viscus and takes some time to roll around inside tank to assure good coverage..
wall coating will slump down to lowest point so keep rotating..

I used less than 1/2 of pint kit some 10 years ago hasn't leaked since..
isn't cheap but provides a thick internal patch unlike some coatings..

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post #3 of 47 Old 07-19-2019, 12:24 PM Thread Starter
 
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"Clean bike, I just need a tank now...,".
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post #4 of 47 Old 07-19-2019, 12:26 PM
 
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post #5 of 47 Old 07-22-2019, 04:28 PM Thread Starter
 
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Giving up on this tank. The more I abrade the insides with small bolts and nuts, the more places this tank weeps through, just under the paint. Ordered one of the "replacement" tanks and will use the casswells on that tank before installing. I think I'd prefer that to worrying about the wife on an iffy tank.

'09 Rebel 250
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post #6 of 47 Old 07-23-2019, 11:26 AM
 
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A new tank is $60-80 shipped. Just FYI.
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post #7 of 47 Old 07-23-2019, 11:35 AM Thread Starter
 
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It's on it's way Craftycrafter, should be here be week's end. 🙂

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post #8 of 47 Old 07-29-2019, 01:58 PM Thread Starter
 
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New tank treated with epoxy and installed. Runs about a mile, shuts off, gas coming out overflow tube under the bike, won't start for about a half hour, then repeats. Ideas? Thanks
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post #9 of 47 Old 07-29-2019, 02:29 PM
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When it stops, remove the gas cap and see if it will immediately start up. If it does, either the breather tube needs to be cleared (more difficult) or the cap needs to be vented. A vacuum is forming because the tank isn't venting. https://www.hondarebelforum.com/f76/...k-31610-2.html

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post #10 of 47 Old 07-29-2019, 03:57 PM Thread Starter
 
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Okay, tried taking cap off, still had to wait 15-20minutes to start. Next step?
Also, where would you drill a cap to assure no vacuum lock in the future? Thanks,

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