How to Fix Dent in Motorcycle Gas Tank

A motorcycle tank is a simple container that stores gas. When the rider fills up the bike’s tank, he is actually pouring fuel into an internal bladder, where it expands and sits until the rider pulls out his key/switch to start the engine. It is one of the most essential parts of a bike. Unfortunately, sometimes dent might occur on motorcycle gas tanks. However, you don’t need to be very much worried about this because today, I will discuss how to fix dent in motorcycle gas tank.

How to Fix Dent in Motorcycle Gas Tank

How Motorcycle Gas Tank Gets Dented?

Motorcycles are a mode of transport that is often associated with speed. This means, if something goes wrong, you could be exposed to fast-moving objects in your surrounding. Not only this, but motorcycles can also get into accidents because of other factors such as bad roads or accidentally hitting an animal on the road. If you own a motorcycle and regularly use it on the road, then there is a high chance that your fuel tank has received its fair share of dents and dings at one point or another.

The Following Are Some Ways How Motorbike Gas Tanks End Up Getting Dented:

If your bike has been involved in an accident (or even comes close), you have probably noticed some damage done to the tank, which may include denting and dings. In some cases, your motorcycle’s gas tank may also have a crack or two in it, but these are usually not very severe.

Dent On Motorcycle Tank

If you ride with friends on your bike, there is a high chance that due to rough riding habits (such as quick braking), your motorcycle might end up hitting the person who is sitting behind you. This type of accident can be excruciating due to the sudden change of direction and force involved, which could damage both riders and passenger’s body parts such as bodies, hands, fingers, and so on.

Motorcycles continue to be produced in different styles adding cool aesthetics, making them less durable than their counterparts from previous years. In addition to this factor, if they do get hit, vehicles such as these are more likely to get damaged due to their brittle parts.

Although the gas tank of a motorbike is made out of a material that is designed to resist cracking and denting, different accidents can make it weaker and prone to damage. For instance, if you fall off your bike during braking or hitting an object on the road with velocity, there is a chance that some parts of the motorcycle, such as its gas tank, will receive severe damage, eventually resulting in dents or cracks.

Step-Wise Guide on How to Fix Dent in Motorcycle Gas Tank

  • Place the motorcycle in a well-lit place and remove all the parts that can be removed with ease. These include mirrors, fuel tanks, lights, etc. The exhaust pipe must also be detached from its bracket or otherwise raised to avoid damage during hammering. Now remove the seat and dismantle the pillion seat. Take away everything, including screws and bolts, which may fall off when you strike at the dent with a hammer. A ratchet handle is best suited for this purpose. It will provide your hands with comfort and leverage, which are essential to do this job properly without damaging yourself or hurting anybody else.
  • Clean off the rust from inside of the gas tank by washing it thoroughly with soap water so that all loose particles come out and do not get inside the tank while hammering.
  • Let the gas tank drain completely before starting work on it. If you are using a power drill, you will need to drain ½ gallon of fuel from one side of the tank only because there is an overflow pipe at that end of the gas tank in most bikes.
  • Apply a generous portion of fiberglass resin on all sides, which have dents by brush or roller, and allow it to dry thoroughly for about half an hour before applying another coat after 2 hours. Allow this process to continue for some time until you achieve sufficient thickness between layers (about 1/8 inch) over the dented area to hold up under hammering later during the welding stage when enough heat will be generated to weld the tank back to normal position.
  • While waiting for the resin to dry, cover a workbench with newspaper and place some old newspapers over it as well because fibers from these sheets may stick to your motorbike gas tank while you are hammering and cause further damage. If you use leather gloves, they must also be covered with newspaper or cloth so that none of them end up stuck on the dent or in between dented areas resulting in uneven surfaces.
  • When the resin is completely dry, take off any paper covers, place the gas tank down on this working bench with its damaged area facing upwards, and then carpet the whole area thoroughly. This is done, so that finished repair does not come undone due to the impact of hammer strokes on hard trolleys.
  • Heat the damaged area with a scorching air gun to about 320 degrees Fahrenheit, which is sufficient to soften the resin and enable you to do hammering without damaging the painted surface of the gas tank or exposing its steel body inside through dent.
  • Once this healing process is complete, take out two wooden blocks of similar size and shape as dented areas for which you will be welding them back later at their place over the dents once a repair has been completed.
Fixing Dent Of Tank

Precautions While Fixing Dent in Motorcycle Gas Tank

When you try to fix a dent in a motorcycle gas tank, you should take the right precautions.

  • Always wear protective clothing while working on the machine and use safety glasses.  Wear rubber gloves if possible.  
  • Use only the duplex tool for fixing the dent.  Do not use any other kind of metal tools as they might damage your tank further or leave marks that can be seen easily when you paint it later.  If nothing else is available for your motorcycle, then ask someone to lend their tank filler neck so that you can put your tailpiece and fuel bulb over it before attempting to remove dents from the tank using a duplex tool or hammer and dolly set. Remember: this is a temporary solution.  You have to buy your own tank filler neck after fixing the dent in the motorcycle gas tank.  
  • If you do not know how to fix dent in motorcycle gas tank, then seek professional assistance.  This way, you can be sure that your tank is restored to its original condition, and it would also save you time and money.
  • While attempting to repair dents from the tank on your own, be very careful while using sharp edges of the hammer and dolly set.   These tools have sharper edges than other types of hammers or dolly sets, which come with shop quality tools like ‘.   So be extra cautious while working with these tools.  The sharp edges may cause the metal to chip off and cut your hands, face, or any other part of your body.
  • While removing dents from the tank using a hammer and dolly set, try not to damage paint in the process.   You might have to remove an excessive amount of paint from some areas around the dent if you are willing to spend extra time on it.  After fixing the dent in the motorcycle gas tank with hammer and dolly set, you will have to repaint the area anyway, so don’t bother about paint removal at this point during the repairing process, as it won’t matter once you actually sand down that spot for a new paint job.


For best results, buy a toolset if you don’t have one already and don’t try to repair dents from the tank on your own without proper tools, experience, or advice from someone who knows how to do it. I hope you have obtained all the information regarding how to fix dent in motorcycle gas tank. Thank you, and have a good day!

You may read also – How to Fix a Slipping Clutch Motorcycle

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