Gas tank issues:

[Lone Rider]

Hello All: I have a 2006 Big Dog K9 Custom. I recently had an issue pop up with the bike running fine and then suddenly stalling out, dying, as if out of gas, although I had a full tank. (I dislike not having a gas gauge)
Anyroad, I got the bike back home, pulled off the tank cap, and noticed that there was some green film on the inside of the filler tube, right at the top where the inner "tank body hole" has a metal insert to allow for the gas cap to screw into. With a small pair of tweezers, I pulled a small bit of this green film stuff of the inner surface, and looked at it. I realized that someone had probably put a sealer inside the tank and now it was possibly breaking loose, and getting caught down in the tank where the pitcock filter screen is, causing partial clogging, and also causing the bike to stumble and die when fuel cannot flow through the pitcock to the carbs.
Question: What would be the best solution to fix this anomoly?
1. pull the tank, buy another and replace it with a new one? (Because I don't know if there were previous rust issues inside and I don't want to have any more new issues with trying to repair this one) or
2. Pull this tank, flush and refill? If so, what would be the best method to do so?
would I need to find a better sealer? if so, what brand? do I really want all this bother?

Any help would be greatly appreciated.......
Ride safe, Ride On!

 

[Unsprung]

If it is the tank liner, get it redone unless you can do it yourself. You can drain the tank, pull it off and verify by pulling the petcock and filter.
I had an 03 Pit that the tank liners started coming apart in. Had both tanks redone at a local shop at about $270 total. You may be able to get a better deal with a single tank. Are you sure it’s not your gas cap check valve?

 

[SKOGDOG]

What Unsprung said. I thought there was a liner issue with one of mine, and Blacktopper and I drained it (easy on a carbed K9), and looked in with a bore scope. Turned out it was fine.
But you need to get a look at it to know for sure, and in your case, it might be a good idea to flush it out with water to see what might have flaked or peeled off. I did that, and followed up by using alcohol, because it goes into solution with any remaining water from flushing.
Some guys have cleared the tank with acid, but that is almost impossible to do without damaging the paint. Some guys didn't re-line the tank and just ride. There are a couple of professional sources, and you can ask after Unsprung's source too. I recall a couple of outfits getting $6-700 to clean and re-line.

 

[SB03chopper]

I had mine relined last year, about $250 here in St. Louis. You could hear my liner inside the tank coming apart.

 

[Lone Rider]

If it is the tank liner, get it redone unless you can do it yourself. You can drain the tank, pull it off and verify by pulling the petcock and filter.
I had an 03 Pit that the tank liners started coming apart in. Had both tanks redone at a local shop at about $270 total. You may be able to get a better deal with a single tank. Are you sure it’s not your gas cap check valve?

I honestly don't know.....I've never owned a Big Dog before now, and never had this kind of issue either. Do Big Dog tanks all have a liner in them? if so......then do I need to send the tank to Wichita, Ks Big Dog facility to have them re line it? I'm in Tulsa, and there are no Big Dog dealers here. I guessing I would have to send the tank off to Wichita to have it done correctly.

 

[Lone Rider]

What Unsprung said. I thought there was a liner issue with one of mine, and Blacktopper and I drained it (easy on a carbed K9), and looked in with a bore scope. Turned out it was fine.
But you need to get a look at it to know for sure, and in your case, it might be a good idea to flush it out with water to see what might have flaked or peeled off. I did that, and followed up by using alcohol, because it goes into solution with any remaining water from flushing.
Some guys have cleared the tank with acid, but that is almost impossible to do without damaging the paint. Some guys didn't re-line the tank and just ride. There are a couple of professional sources, and you can ask after Unsprung's source too. I recall a couple of outfits getting $6-700 to clean and re-line.

I live in Tulsa, and there are no Big Dog dealerships here, and I don't want to take the tank to a Harley place, too pricey; other than that, I may have to find a local non dealership kind of repair shop that would be able to reline the tank. I don't know....I guess I will just remove the tank, flush it out with water, let it dry completely; clean the pitcock, then reinstall the tank, fill it with a gallon of nonethanol, and see if that solves the "out of gas syndrome"...or not. After that, I will have to look into having someone re line the tank. what do you think?

 

[Lone Rider]

I had mine relined last year, about $250 here in St. Louis. You could hear my liner inside the tank coming apart.

I had initially planned to remove the tank, empty it, flush with water, dry it out completely, clean out the drain filter, and then replace the tank, and refill with fresh non ethanol gas. That is, until I saw the liner peeling away from the top opening; that opens a whole new can of worms to deal with.

 

[Unsprung]

I had initially planned to remove the tank, empty it, flush with water, dry it out completely, clean out the drain filter, and then replace the tank, and refill with fresh non ethanol gas. That is, until I saw the liner peeling away from the top opening; that opens a whole new can of worms to deal with.

Some radiator shops can clean and re-line at reasonable cost. No need to send the tank to Big Dog. Lots of local shops to ask around about or google it. May even be able to ask a fellow rider. Check out the members map for any active members in your area who may be willing to help you out. I can get it to the guys who did mine but you’d have to ship your tank to Florida. Someone closer to Tulsa may chime in tomorrow since it is past most folks bedtimes now including mine. Let us know what you decide and lots of help in these pages.

 

[Mr. Wright]

You need to get a look at the inside. Also pull the petcock out and see how much of the liner is stuck to the screen. I just bought an 04, and found the liner peeling at the top, but when I pulled the petcock, there was very little stuck to the screen. I just put about a half gal of gas back in it and shook it really good. A little bit came out when I drained it out, and haven't had any problems since. I may have to do it again before riding season just to make sure more didn't come loose. Keeping the tank full when storing will help keep it from peeling.

 

[SKOGDOG]

You need to find a business that can do the tank. I guarantee if you take that tank to any motorcycle dealer, they will send it out to a specialty shop. You might start by asking the HD service manager what shop he would use to re-line a tank that has a peeling liner.
Or ask an Independent HD shop who they would use and get ahold of them.
Or p.m. Unsprung and see who did his and ship it to St. Louis.
You need to be very pointed when you ask if they guarantee that they can do this without ruining your paint, because even guys who know what they're doing can have chemicals spill that mar the paint. It looks like your bike is basic black? If so, don't sweat it and figure you'll have to pay to have it repainted if it gets ruined. It is not easy to remove the liner and put in a new one without disturbing the paint.
But as Mr. Wright recommends, first things first...drain and pull the tank and have a look.

 

[BWG56]

Pull the tank and remove the petcock, let it sit for a week or 2 empty and the liner will dry out like a snake skin. Throw a few nuts in the tank and shake it to break up the liner and vacuum out the liner chips. The tanks were pressure tested to 10psi and I've been running without a tank liner for 4 years without a problem, but I do pull the petcock every year to remove the debris from the petcock screen from all the junk in the gas from filling it.

 

[Lone Rider]

Some radiator shops can clean and re-line at reasonable cost. No need to send the tank to Big Dog. Lots of local shops to ask around about or google it. May even be able to ask a fellow rider. Check out the members map for any active members in your area who may be willing to help you out. I can get it to the guys who did mine but you’d have to ship your tank to Florida. Someone closer to Tulsa may chime in tomorrow since it is past most folks bedtimes now including mine. Let us know what you decide and lots of help in these pages.

Interesting.....I didn't think of using a radiator shop to clean and reline the tank.....that's a great idea! thanks!

 

[Lone Rider]

You need to find a business that can do the tank. I guarantee if you take that tank to any motorcycle dealer, they will send it out to a specialty shop. You might start by asking the HD service manager what shop he would use to re-line a tank that has a peeling liner.
Or ask an Independent HD shop who they would use and get ahold of them.
Or p.m. Unsprung and see who did his and ship it to St. Louis.
You need to be very pointed when you ask if they guarantee that they can do this without ruining your paint, because even guys who know what they're doing can have chemicals spill that mar the paint. It looks like your bike is basic black? If so, don't sweat it and figure you'll have to pay to have it repainted if it gets ruined. It is not easy to remove the liner and put in a new one without disturbing the paint.
But as Mr. Wright recommends, first things first...drain and pull the tank and have a look.

Yeah, it's black onyx. Thanks for the idea.

 

[BWG56]

Here's a year of normal junk on the petcock

 

[HMAN]

Im in Wichita and I used a local paint shop. But he was a BDM employee @ one point. I think he did it for $120? I'll have to check records to be sure. They do make a kit that you can reline @ home. J&P sells it I believe...? Not sure if the paint shop is still in biz, this was a few yrs back.

 

[Lone Rider]

Pull the tank and remove the petcock, let it sit for a week or 2 empty and the liner will dry out like a snake skin. Throw a few nuts in the tank and shake it to break up the liner and vacuum out the liner chips. The tanks were pressure tested to 10psi and I've been running without a tank liner for 4 years without a problem, but I do pull the petcock every year to remove the debris from the petcock screen from all the junk in the gas from filling it.

I have removed the tank, gashole ring, and pitcock.....and what did my peering eyes behold? Several large pieces of liner, up to 2" rattleing around inside. So......I spent a couple of hours on my back in the yard, with the tank up over my face, while holding a small flashlight in my mouth, and looking up to the sky while shaking the shit out of the tank, and every 12th shack or so, a piece would manage to fall right over the tank hole, where I would try and pull out a piece with a small pair of needle nose pliars, while my lady would hold the tank steady. Two hours of this and I finally got all the loose pieces out. After that I took a break and had a cold beer.

 

[Lone Rider]

Interesting.....I didn't think of using a radiator shop to clean and reline the tank.....that's a great idea! thanks!

I did call a local radiator place, and for $85 they can put some liquid into the tank. swish it around and "melt" the liner down to bare metal inside the tank. No need for dipping the entire tank under, thus, saving the paint. After I get this done, I think I will take off both fenders and send all three tins out to have them repainted anyways. yep yep .

 

[Unsprung]

Glad it’s not a mystery anymore. Those pesky liners suck when they come apart. If mine comes apart I’ll remove and leave it bare.

 

[Lone Rider]

Im in Wichita and I used a local paint shop. But he was a BDM employee @ one point. I think he did it for $120? I'll have to check records to be sure. They do make a kit that you can reline @ home. J&P sells it I believe...? Not sure if the paint shop is still in biz, this was a few yrs back.

Yep. You might have seen my other recent postings regarding my progress so far. But to catch you up; I did remove the tank, and all hardware; spent a couple hours shaking the tank and pulling out several pieces of tank liner; next I found a local radiator place that can clean out my tank for only $85 using a liner melting solution, not acid, and therefore save the paint. When this is done, I think I'll send the tank, and both fenders off to a place to have them all repainted, thus.

 

[francoblay1]

I have removed the tank, gashole ring, and pitcock.....and what did my peering eyes behold? Several large pieces of liner, up to 2" rattleing around inside. So......I spent a couple of hours on my back in the yard, with the tank up over my face, while holding a small flashlight in my mouth, and looking up to the sky while shaking the shit out of the tank, and every 12th shack or so, a piece would manage to fall right over the tank hole, where I would try and pull out a piece with a small pair of needle nose pliars, while my lady would hold the tank steady. Two hours of this and I finally got all the loose pieces out. After that I took a break and had a cold beer.

Please define "rattling" ... I´ve got a very obnoxios PITA rattling LOUD noise in my tank which I´ve always believed comes from that useless tube inside it... now you got me thinking...