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**sunilg** · 09-17-2012, 05:17 PM

Query approved.

**muztariq** · 09-17-2012, 11:27 PM

Originally posted by pulsarized View Post

Hi Guys,

ALERT P180 UG4 Owners! I own a P180 UG4 for 3 years.

I've a problem with my P180 UG4. Holes around 2-3 mm in diameter have developed on my petrol tank.

Some Introduction to the issue:-
I once went to collect my bike from my mechanic after a regular service.He had a bottle full of some sludge like thing. It was a mixture of petrol water and rust.It filled a 2 ltr coke bottle upto half of its capacity.
He told me that the hole which is generally present in the petrol tank(under the fuel lid) for draining the rain water has clogged due to rust and thus water has moved into the petrol tank.
He said that the petrol tank lid needs to be covered.He asked me to buy a tank cover which covers the lid.(I have a tank cover which leaves the lid open).
When i had bought the bike,the same was said to me by a neighbor who owns the p150 classic. He claimed to have retrieved 1 litre of water from the petrol tank.So he advised me to use a cover which covers the lid.

Last time when i had given my bike for service, my mechanic told me that there is a hole on the tank and he has used m seal to block the leakage! He told me to look for any leakage and tell him if i found any.
I was roaming happily thinking that the issue was over and not a serious one.

After 2 weeks i found that my mileage has dropped from around 48 to 44.The next week i found that my mileage was even lesser (around 41).
I filled petrol worth 200 bucks and came home on sunday morning and had left my bike on its side stand.(16 Sep).
When i returned i noticed that it was smelling petrol near my bike. When i bent down i was shocked to see petrol leaking(Dripping). I noticed that the paint on the scoop and tank started to peel after being soaked in petrol.

Then i tried to feel the hole on the tank and the moment i touched the leaking spot, the rust gave way and hole became bigger and petrol started to pour. After a long battle i stopped the flow(almost emptied the tank) with Adhesive Tape and drove the bike to a nearby mechanic.(Completely new guy).

Even this mechanic pointed out that i should have full petrol tank cover. Then i had the holes covered and some paste applied over it.Cost me 170 bucks.

Now I am really worried about this leakage problem. I have a few questions!

1.Is there a chance that there may be weak spots on other areas of my fuel tank?
2.Can they develop into holes too?
3.Do i have to replace my tank and any idea as to how much, replacing the tank would cost?
4. Is this a frequent problem in Pulsar. I have seen many pulsars without fuel tank cover.Do they also suffer the same?

Sorry for the long post.
Thanks in advance for your replies.

You are riding very unsafe. Get the whole tank removed and see the condition of the tank. If manageable, do proper welding or the best way is to replace the whole tank and put a new petrol lid.

Never ride with patched up tank.. Petrol burns so fast that you wont even get time to step down if something happens!

**pulsarized** · 09-18-2012, 10:24 AM

Originally posted by muztariq View Post

You are riding very unsafe. Get the whole tank removed and see the condition of the tank. If manageable, do proper welding or the best way is to replace the whole tank and put a new petrol lid.

Never ride with patched up tank.. Petrol burns so fast that you wont even get time to step down if something happens!

I got the tank removed and inspected it. There was one significant hole and 3 more holes were about to develop.The mechanic dint just patch it up. He said that he was going to rivet it. Not really sure what he has done. Any idea how much pulsar petrol tank costs?
Thanks for your input.

**muztariq** · 09-19-2012, 12:48 AM

Originally posted by pulsarized View Post

I got the tank removed and inspected it. There was one significant hole and 3 more holes were about to develop.The mechanic dint just patch it up. He said that he was going to rivet it. Not really sure what he has done. Any idea how much pulsar petrol tank costs?
Thanks for your input.

Better test it well. The new tank may be 1200-1500 INR. The list here shows 890 something in 2009.

Attached Files

**Pinaki** · 09-20-2012, 02:10 AM

Immediately replace the fuel tank and the fuel petcock and the fuel pipe etc . Also have the carburetor cleaned throughly .
These circular recessed tank cap's which allow water to enter and then tries to drain it off thru a drain hole is one of the worst possible design flaws I have seen in motorcycles till date . I drained more than a liter of rusty orange water today from my friend's wind125 tank(which has this type of cap) . Moreover this type of tanks cannot be fully drained by turning it upside-down , I found . You have to dismantle the fuel petcock to do get complete drainage .

**sibun** · 09-20-2012, 09:08 AM

Just change the fuel tank. It cost around Rs. 4k. Welding is an option but it depends on the skills of the person. Also, applying M-seal will make it ready for 6 months and after that you can go for new tank if finance condition is not good at present. But applying m-seal is a trick and if properly applied will ensure no leakage after even 2 years. But it is better to go for new tank.

**Ayson** · 09-22-2012, 01:58 AM

1) Since more than one hole has developed, your entire tank should be considered unsafe. The entire sump of the tank would have rusted, which will give way.

2) Most probably yes, with your description, there is a high chance that as you patch one hole, another will follow. Also the Pulsar tank has about 3 sump areas. So all those places may develop leaks.

3) Best bet is to replace. New tank costs INR 4500 +/-200 for midnight black. Other colours are more expensive by INR 200 - 300.

4) Not a frequent problem.

The reason for your predicament is the clogged drain pipe. When i wash, i pour water directly on the filler lid, because i know it will flow right out of the drain pipe. The drain pipe HAS to be kept clean. This cannot clog due to rust because the drain hose is rubber. Dirt and debris, on the other hand can clog it. Once clogged, water will rise till it overflows the raised edge of the filler hole and into the tank. If you suspect it is blocked, use a wire to clean it. When you wash, pour water on the fuel lid and make sure you can see it flow out freely at the bottom of the bike.

Considering you and your neighbour have the same problem, the cause might be where you park. Small leaves from a tree or small seeds etc may be falling on your bike and entering the drain hose over a period of weeks and blocking it. I have a 2007 Pulsar (ie 4 years old) with no tank cover, and i have never drained a drop of water from its tank, even after thorough washing.

Tank covers 1) will trap dust and dirt in bertween it and will scratch up your tank, and 2) are FUGLY.

Replace tank ASAP, flamable drops of petrol dripping onto a hot cylinder head / exhaust manifold, and you know the rest.

Originally posted by muztariq View Post

Better test it well. The new tank may be 1200-1500 INR. The list here shows 890 something in 2009.

Those prices are not in INR and is for UG-3 or earlier from what i remember.

**pulsarized** · 10-08-2012, 04:41 PM

Thanks muztariq. Thanks for all the details. I think the tank costs around 4-5k . Money is not a big deal here. I am not really sure as to how long it will be before the tank starts leaking again( the new tank).
Right now the patched tank seems to be ok.
But Replacing the tank is in my mind and will be done sooner or later. Thanks again.

**pulsarized** · 10-08-2012, 04:42 PM

Originally posted by Pinaki View Post

Immediately replace the fuel tank and the fuel petcock and the fuel pipe etc . Also have the carburetor cleaned throughly .
These circular recessed tank cap's which allow water to enter and then tries to drain it off thru a drain hole is one of the worst possible design flaws I have seen in motorcycles till date . I drained more than a liter of rusty orange water today from my friend's wind125 tank(which has this type of cap) . Moreover this type of tanks cannot be fully drained by turning it upside-down , I found . You have to dismantle the fuel petcock to do get complete drainage .

Yes I am planning to get the tank replaced.
Its the better option in the longer run.
It will give me better peace of mind.
Thanks for the reply.

**pulsarized** · 10-08-2012, 04:43 PM

Originally posted by sibun View Post

Just change the fuel tank. It cost around Rs. 4k. Welding is an option but it depends on the skills of the person. Also, applying M-seal will make it ready for 6 months and after that you can go for new tank if finance condition is not good at present. But applying m-seal is a trick and if properly applied will ensure no leakage after even 2 years. But it is better to go for new tank.

Considering the weather conditions it is better to go for a new tank.
The mseal that my mechanic used dint last for more than 2 weeks.
And also new holes started showing up.
I am gonna replace the tank.
Thanks for the reply

**pulsarized** · 10-08-2012, 04:49 PM

Originally posted by Ayson View Post

1) Since more than one hole has developed, your entire tank should be considered unsafe. The entire sump of the tank would have rusted, which will give way.

2) Most probably yes, with your description, there is a high chance that as you patch one hole, another will follow. Also the Pulsar tank has about 3 sump areas. So all those places may develop leaks.

3) Best bet is to replace. New tank costs INR 4500 +/-200 for midnight black. Other colours are more expensive by INR 200 - 300.

4) Not a frequent problem.

The reason for your predicament is the clogged drain pipe. When i wash, i pour water directly on the filler lid, because i know it will flow right out of the drain pipe. The drain pipe HAS to be kept clean. This cannot clog due to rust because the drain hose is rubber. Dirt and debris, on the other hand can clog it. Once clogged, water will rise till it overflows the raised edge of the filler hole and into the tank. If you suspect it is blocked, use a wire to clean it. When you wash, pour water on the fuel lid and make sure you can see it flow out freely at the bottom of the bike.

Considering you and your neighbour have the same problem, the cause might be where you park. Small leaves from a tree or small seeds etc may be falling on your bike and entering the drain hose over a period of weeks and blocking it. I have a 2007 Pulsar (ie 4 years old) with no tank cover, and i have never drained a drop of water from its tank, even after thorough washing.

Tank covers 1) will trap dust and dirt in bertween it and will scratch up your tank, and 2) are FUGLY.

Replace tank ASAP, flamable drops of petrol dripping onto a hot cylinder head / exhaust manifold, and you know the rest.

Those prices are not in INR and is for UG-3 or earlier from what i remember.

That was a detailed explanation.
Even i had the same explanation for "How water could have gotten into my fuel tank".
I am planning to get my tank changed.
I don plan to change my bike for another few years.Also i recently upgraded the rear tyre.
So changing the tank will be a sensible option.

I have been using the petrol tank cover and my tank is not that scratched. Its pretty new.
But i have seen a lot of pulsars without tank cover( the pulsar tank in all its glory) , so rain water seepage should not be an inherent problem.

It would be good to check the drain pipe regularly to make sure it is not clogged.
Usage of a wire to clean the drain pipe is a good technique and i dint think of it.Will be helpful.

Will check for the tank cost and post it here when time permits.

Thanks for the reply.

**Natfx7** · 11-11-2012, 07:57 PM

Hi pulsarized,

I found some strange 1 mm hole on my Pulsar 180 UG4 silencer pipe while cleaning with my face down under it. It does not look like rusty hole. Is it normal factory default ? Do I have to use M-Seal ?

It is better to change your fuel tank. I have Pular 180 UG4 all spare parts price list in a pdf file. I can't upload the .pdf due to the size limit. Here is the screenshot of UG4 fuel tank price list.

Attached Files

Announcement

Hole in My Fuel Tank - Pulsar 180 UG4

Hole in My Fuel Tank - Pulsar 180 UG4

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