2003 Chopper S&S 107

[Buzzinbooch]

Getting ready to remove varnish from the tank, I have a question related to the tank bungs located underneath the tank connected via 1/4” braided fuel line. What is its purpose? Is this a venting system, fuel equalization? Both side are completely blocked. I can’t not blow or suck air through. Is it possible it is cosmetic?
I would think of it was fuel stabilization and it was blocked, when inserting weed whacker line it might feel a little spongy or a little give. It is solid, and both sides allow for the same length of whacker line when inserted.


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[Rottweiler]

If you have a split tank the two halfs should be connected with a cross hose that keeps both sides at the same level.

 

[Buzzinbooch]

Single tank but still have a cross tube on the chopper.


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[Buzzinbooch]

Now I’m thinking cosmetics


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[Buzzinbooch]

Was thinking about using acetone to remove varnish from inside the tank, any recommendations?


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[HMAN]

Was thinking about using acetone to remove varnish from inside the tank, any recommendations?


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Make sure you tape the heck outta the tank if you do that. How much varnish ya talking? Id try clean gas first. Swirl that around for a while. A bit safer than acetone imo.

 

[Buzzinbooch]

I’ve been running clean gas for a bit now, there’s a pretty nice layer of varnish on the bottom of the tank. I’ve had a couple issues with clogged jets in the carb. I could leave it and run an inline fuel filter as there isn’t one today. The acetone scares the hell out of me, the paint on the bike is flawless.


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[Snuffy]

I would definitely recommend a fuel filter

 

[Buzzinbooch]

Rottweiler, HMAN and Snuffy. Appreciate your responses to my post. I’m not very active on the forum. I need to change that.


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[HMAN]

I’ve been running clean gas for a bit now, there’s a pretty nice layer of varnish on the bottom of the tank. I’ve had a couple issues with clogged jets in the carb. I could leave it and run an inline fuel filter as there isn’t one today. The acetone scares the hell out of me, the paint on the bike is flawless.


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Are you seeing actual varnish or perhaps a colored liner? Lots of these tanks were 'lined' from the factory. After time the liner will flake off and cause issues. Relining can fix it. Or removing the liner altogther? But a fuel filter will help either way. Keep it filled and rolling and Id bet you'll be good. Keep us posted.

 

[Buzzinbooch]

Definitely keep ya posted, I’m pretty sure it varnish, light green in color.


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[HMAN]

Definitely keep ya posted, I’m pretty sure it varnish, light green in color.


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That sounds like liner color. They used a green. Ive got it on both the 04 Chopper and 04 Pitbull. I'd bet its liner. Drain n dry ur tank. Bet its still greenish. Varnish is usually a brownish color from my experience.

 

[Buzzinbooch]

That sounds like liner color. They used a green. Ive got it on both the 04 Chopper and 04 Pitbull. I'd bet its liner. Drain n dry ur tank. Bet its still greenish. Varnish is usually a brownish color from my experience.

Drained and dried the tank the other day. Still green. Pulled the bowl off the carb and it was clean. You’re probably correct on it being the liner. I’ll fill it with gas and install a filter and call it good. Really appreciate the knowledge this site has. I was close to dumping a quart of acetone in the tank and I’m 95% sure I would have messed up the paint. Saved my ass!


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[Rottweiler]

Yes I believe you will be fine with a inline filter. Acetone will eat the paint quick.

 

[Chong]

My experience..
I triple wrapped tank. Tape, brush on liquid mask, plastic.
Still got some paint damage, leaked at pitcock. You like your paint i wouldn't attempt it . There are a couple places that will relign it. Cheaper then a repaint . And acetone won't touch the old liner material.