2006 Rebel Tank Replacement - Honda Rebel Forum
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post #1 of 10 Old 05-20-2019, 01:13 PM Thread Starter
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2006 Rebel Tank Replacement

I recently purchase a 2006 that has been sitting since 2010. The previous owner left half a tank of fuel in it and the tank is shot. It is rusted beyond belief inside and sounds like you are shaking a can or rice when you move it. Easiest open is to replace the factory tank. The problem I'm running into is my current tank has a vent port in the under side of the tank. Any new tanks I am finding are unvented and I worry about vapor locking in the summer. Can I make the switch and if so do I need a special vented cap?
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post #2 of 10 Old 05-20-2019, 01:42 PM
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Welcome to the forum. You're tank is probably slavageable, especially if you line it with Caswell epoxy tank sealer. The mini kit is all that's needed. https://www.caswellplating.com/epoxy...-to-5-gal.html

The aftermarket Chinese tanks are hit and miss. Some leak out of the box, some leak after being used a while, and a few never do. If you choose to get one of those, I would also recommend sealing it with Caswell before ever putting fuel in it.

If you need to vent the cap, here is a thread on the subject. Be sure to read the entire thread before reaching for the drill. https://www.hondarebelforum.com/f76/...ank-31610.html

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #3 of 10 Old 05-20-2019, 01:59 PM Thread Starter
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I would love to save my old tank the bike only has 800 miles on it and its in great shape on the outside however the inside is destroyed and only half the petcock came out when I removed it. The tank I am looking at is sold by TCMT. Thank you so much for your help
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post #4 of 10 Old 05-20-2019, 02:41 PM
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Did all of the metal parts come out of the old tank? I'm assuming the upper, nylon filter screen is what remained in the tank? If so, it's no big deal, even if you can't get it out, but you may be able to grab it with needle nose pliers. If you want to use the old tank, get the Caswell and follow their directions. Because the epoxy provides additional strength to the tank, even tanks with holes in them can be repaired. Just tape over the holes, prep the tank according to directions, and line the tank. Then install an inline fuel filter to keep any contaminants in the fuel from reaching the carb and fouling it. I like the see-through filters so I can see if there is any crud on the filter https://www.hondarebelforum.com/f39/...ter-13278.html

A tank treated with Caswell will never rust because all the metal is sealed off.

The TCMT tanks are Chinese, and what I said about them earlier is applicable.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #5 of 10 Old 05-20-2019, 02:52 PM Thread Starter
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I have drained the tank and refilled it a few times however I can still here stuff sloshing around in the tank and cannot seem to get it all out. It sounds like quite a large amount of debris.
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post #6 of 10 Old 05-20-2019, 08:26 PM
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Here's a thread on tank cleaning: https://www.hondarebelforum.com/f39/...ning-7168.html

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #7 of 10 Old 07-11-2019, 10:54 AM
 
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So, these aftermarket larger chinese tanks don't seem to have a very good reputation. Is there anybody out there who sells a larger-capacity tank for the Rebel 250 with a more favorable reputation?

.

2016 Rebel 250 - - Black
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post #8 of 10 Old 07-11-2019, 11:48 AM
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With the stock tank, you can expect to travel 125 miles or before needing to refuel. Most of us welcome fuel stops by then, if not sooner, just to get butt relief and walk around a little. I personally don't see the need for a larger tank. BTW, those tanks are more prone to being dented because the are considerably wider.
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Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #9 of 10 Old 07-11-2019, 01:09 PM
 
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Thanks for that feedback, flitecontrol. I see what you mean about welcoming the pit-stops every couple hours - - makes perfect sense.

And it never occured to me about the increased dent potential. Very good point!

Maybe the best approach for extending range is to carry an additional small jug of gas on a rear rack or similar. That way you only carry it when necessity dictates, but the rest of the time you keep the bike clean and oem.

2016 Rebel 250 - - Black
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post #10 of 10 Old 07-11-2019, 01:37 PM
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If you are travelling where gas stations are more than 50 miles apart, I would agree that carrying extra fuel would be a good idea.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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