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Re: looking to repair or replace gas tank - old liner...
Google " motorcycle salvage yamaha " and see what you can find. Babbit's shows three 650 models for 1982. They have a new tank for a 1982 XJ650J @ $355.00. Other than those suggestions, perhaps a re-coat of sealer? Google“ kreem fuel tank liner “or go towww.http://www.4secondsflat.com/Fuel_Tank_Sealer.html Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx
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Has it been sitting any length of time? Often internal gas lines fall apart. Look in the gas tank to see if there are loose pieces of tubing, the fix for this is to replace the tubing. Do you have fresh mixed gas? Do you have a new spark plug? These are the most common reasons I know.
I usually install/add a union to bottom of pressure switch.. I makes it easy to remove and re-install the switch later if needed. Unions come in brass or steel and sold thru all lumber /plumbing stores. Good luck with your repair.
check for a clog in the toilet valve supply as the washer can deteriate or the old piping in the house can clog if they are old and made of galvanize pipe or the fill valve is clogged. replace valve and or fill valve in the tank
I suggest cleaning out the fuel tank I also recommend installing a NEW fuel filter, New fuel lines and a new primer bulb. This will take care of the fuel system for awhile. All of these parts are available on Ebay, by many online vendors or at small engine repair shops everywhere. Take the old lines with you so you get the correct size and get at least 1 foot of each size you need. You will need the extra length to be able to pull the main fuel line thru the tank to install the NEW fuel filter you get. Even if you use your old filter (not recommended) you will need extra length to reinstall it.
Did you happen to get resolution on this? My gas cap on my 04 1100 classic just fell apart this weekend. It looks like there might be some screws that rattled out and now I'm concerned that I have parts loose in the tank. I didn't spend the $$$ on a new cap yet as I was looking for options. Just doesn't seem right for a cap to just fall apart.
have you check your spare tank?? you might be picking up trash from it. it sits on the right hand side under you seat. have you replaced your hoses? that could be another thing to look into, when the get old the start to break down and i have seen the inside of old rubber hoses fall apart. also make sure that you fuel pump is working right. let me know if you have any other questions about your problem i'll be glad to help M.Woodring
Inside your tank, attached to the fuel pump stem, is a floating device sende rattached to a variable resistor. The float rides on top the gas, sending its position to the gauge as the gas is used and it sinks down. You have a problem there, most likely a new sender is needed. If the car is old, given that you have to pull the tank out it would make sense to replace the sender AND the fuel pump. You can buy a repair manual on CD very cheap on ebay, or you can look around on www.youtube.com, perhaps someone made a video of their experience in pulling a toyota tank and replacing the fuel pump. All models are going to be similar.
Plastic tank? If so, I suggest it is due to old age and/or the new 10% ethanol gasoline. I had a plastic funnel crack and fall apart on me that I'd had for years. I was pouring the new gas through it when it fell apart, maybe a co-incidence, but I think it was the gas.
Depending on the brand of line you use, Tygon line is self sealing but seems to shrink faster then factory supplied because of the ethanol in the gas. The stone gas filter is designed to fall to the lowest part of the tank, not stop the line from falling out.
Hoping the exhaust system is original equipment and undamaged, After replacing the tank a3rd time, I would ABSOLUTELY assess the condition of all exhaust hangers, and re-align exhaust pipes AWAY from that gas tank. The vehicle will best be repaired on a lift, along with some heavy bars. Maybe the closeness of the exhaust was trying to bring your unleaded to a boil. Repair this ASAP