1985 XJ700 Maxim X Plastic Stuck in Gas Tank

Howdy all, I just picked up a 1985 XJ700 Maxim X a few days ago and began to do some work on it. It's been sitting in a garage for the last 13 years and I've been working on a few of the issues it's got. First I wanted to take care of the rust in the gas tank. The gas cap was rusted shut but after two days of using some liquid wrench and dry lube I freed up the lock but I was also having trouble getting the lock mechanism within the tank unstuck. I took out the petcock and shot some liquid wrench in there to loosen it up and it worked, but the previous owner said he had shot some WD-40 in the tank and got the plastic straw got stuck in there! My main question is whether or not that will affect the rust removal or the operation of the bike after the fact. I have some metal rescue that says it's non-toxic and eco-friendly and they say you don't even need to wear gloves when handling but I am unsure as to how it will affect the project in general. I do also plan to use some sort of tank liner but I am not sure what is best to use either. Any and all help is appreciated. Thanks.

Medici

 

If you are going to use a tank liner you will need to get it out.

 

Srain the tank. Remove the fuel sending unit and petcock. Make blanking caps for both holes. Pour in some MEK and dissolve the plastic straw (probably. you may want to try a few solvents on a new straw to see if it will dissolve).

Straw is now gone, and the tank is ready for an epoxy-based liner.

 

I'm assuming you meant "fuel sensing unit"? I was going to ask because it felt as if it is glued to the tank. May seem like a dumb question but is it removable? I'm having a hard time getting it out. I think I'm going to leave the straw in the tank through the degreasing process of the refurb and try to fish it out once it's unstuck from the walls of the tank. I was told that if I did a liner that it would cover over it anyway and wouldn't be a big deal, but I would still prefer to remove it if possible.

Also how would I go about making a plug to cover the remaining holes for the petcock and the fuel sensor? I see you mentioned making blanking caps but I am unfamiliar. Thanks.

(UPDATE) I got the fuel sensor out but it's incredibly dirty, as is the petcock. What's the best way to clean these up and get a new filter for the petcock?

Medici

 

I meant fuel sending unit. That's what the float assembly for measuring the fuel level is called. The potentiometer "sends" a varying voltage to the fuel gauge that is used as a refrence for the fuel level.

Start a conversation with Chacal for all of your parts needs.

You can clean the rust off of the fuel snding unit with vinegar and a rag. That will minimize the risk of damaging it, but it will take longer to get it clean.