Types of Motorcycle Spare Gas Tanks
A motorcycle spare gas tank is an essential accessory for riders who frequently travel long distances or venture into remote areas where fuel stations are scarce. Spare tanks come in various materials and designs, each offering unique advantages in terms of weight, durability, aesthetics, and performance. Choosing the right type can significantly enhance your riding experience and safety.
Steel Tanks
Steel has been a traditional material used in motorcycle fuel tanks for decades. Known for its robustness, steel offers excellent impact resistance and longevity.
Advantages
- High impact resistance
- Durable over time
- Resistant to punctures
- Cost-effective option
Limitations
- Heavier than other materials
- Prone to rust if not properly coated
- More difficult to shape into custom forms
Best for: Touring bikes, heavy-duty motorcycles, and riders prioritizing durability
Aluminum Tanks
Aluminum is a popular choice among modern motorcyclists due to its favorable balance between strength and lightweight properties. These tanks are often found on adventure and dual-sport bikes.
Advantages
- Lightweight yet strong
- Corrosion-resistant
- Easier to repair with proper techniques
- Offers a sleek, premium look
Limitations
- More expensive than steel
- Requires specialized welding for repairs
- Potentially dents more easily under heavy impact
Best for: Adventure bikes, off-road motorcycles, and custom builds
Composite Tanks
Made from advanced materials like fiberglass or carbon fiber, composite tanks represent the cutting edge of motorcycle spare tank technology. They offer exceptional weight savings and aesthetic versatility.
Advantages
- Extremely lightweight
- Excellent corrosion resistance
- Can be molded into aerodynamic shapes
- Modern, high-tech appearance
Limitations
- Higher cost compared to metal tanks
- Repairs require special materials and expertise
- Potential for delamination over time
Best for: Racing bikes, high-performance machines, and show bikes
Plastic Tanks
Plastic spare gas tanks are commonly used in dirt bikes and smaller motorcycles. They provide a budget-friendly and versatile alternative to metal tanks.
Advantages
- Very lightweight
- Impact-resistant
- Inexpensive manufacturing costs
- Easy to customize in design
Limitations
- May degrade from prolonged UV exposure
- Possible fuel permeation issues
- Less durable over extended use
Best for: Dirt bikes, trail bikes, and small commuter motorcycles
Aftermarket Gas Tanks
Aftermarket tanks are produced by third-party manufacturers and offer customization options beyond what OEM parts provide. These tanks can be made from any of the above materials but tailored for specific needs or styles.
Advantages
- Customizable size and shape
- Increased fuel capacity options
- Enhanced aesthetics and style choices
- Versatile fitment across different models
Limitations
- Quality varies between brands
- Installation may require modifications
- Potential compatibility issues with OEM systems
Best for: Custom builds, long-distance touring, and personalization enthusiasts
| Type | Weight | Durability | Cost | Best For |
|---|---|---|---|---|
| Steel | Heavy | Excellent | Low | Touring, heavy bikes |
| Aluminum | Moderate | Good | Moderate-High | Adventure, dual-sport |
| Composite | Very Light | Good | High | Racing, show bikes |
| Plastic | Light | Fair | Low-Moderate | Dirt bikes, small bikes |
| Aftermarket | Varies | Varies | Varies | Custom builds, touring |
Expert Tip: When selecting a spare gas tank, always consider your riding environment and fuel availability. Riders in arid or remote regions should prioritize corrosion resistance and larger capacity, while racers might focus on lightweight materials and aerodynamics.
Specifications and Maintenance of Motorcycle Spare Gas Tanks
Key Specifications to Consider
Selecting the right motorcycle spare gas tank involves evaluating several critical specifications that directly impact usability, safety, and performance during long rides or off-road adventures.
Capacity
The fuel capacity of a spare gas tank typically ranges from 1 liter to 5 liters or more, depending on the intended use and rider preferences. Smaller tanks are ideal for short trips and urban commuting, while larger capacities are preferred by adventure riders or those traveling in remote areas where refueling stations are scarce.
It’s important to balance extra range with weight considerations — additional fuel adds mass that can affect handling, especially on lighter motorcycles. For most dual-sport or touring applications, a 2-3 liter tank offers an optimal compromise between extended range and manageable weight.
Material Composition
Spare gas tanks are commonly constructed from stainless steel, aluminum alloys, or carbon fiber composites. Each material offers distinct advantages:
- Stainless Steel: Highly durable and resistant to punctures, but heavier than other options.
- Aluminum: Lightweight and corrosion-resistant, making it a popular choice for many riders.
- Carbon Fiber: Extremely lightweight and strong, though often more expensive and less common for practical spares.
Material selection also affects heat retention and fuel evaporation rates, which is particularly relevant in hot climates.
Dimensions
Average dimensions for spare gas tanks range around 30 cm in length, 15 cm in width, and 10 cm in height, though this varies based on capacity and mounting location. Compact designs are essential for ensuring compatibility with different motorcycle types — especially street bikes, cruisers, and dirt bikes with limited storage space.
When choosing a tank, ensure it fits securely without obstructing lights, license plates, or passenger seating. Many modern spare tanks feature contoured shapes designed to fit neatly behind the seat or on rear racks.
Mounting Options
Most spare gas tanks mount using straps, brackets, or clamps that attach to the motorcycle’s seat rails, rear rack, side bags, or tail section. The mounting system should be robust enough to prevent movement at highway speeds and over rough terrain.
Quick-release systems are becoming increasingly popular among touring riders who need to frequently remove and reinstall the tank. Always verify that your motorcycle has compatible mounting points before purchasing a specific model.
Dispenser Mechanism
An effective dispenser is crucial for safe and spill-free fuel transfer. High-quality spare tanks include anti-siphon valves, self-sealing caps, and flexible nozzles that allow easy access to the motorcycle's main fuel tank opening.
The dispenser should open only when actively pouring and close automatically to prevent fuel leakage during transit. Some models also incorporate built-in filters to catch debris before it enters the engine.
Safety Features
Safety is paramount when carrying extra fuel. Reputable spare gas tanks include features such as:
- Pressure Relief Valve: Prevents dangerous pressure buildup due to temperature changes.
- Anti-Static Grounding Point: Reduces the risk of static electricity igniting fuel vapors.
- Leakproof Design: Ensures secure containment of fuel even under vibration and movement.
Look for tanks that meet DOT or ISO safety standards for added peace of mind.
| Feature | Importance | Recommendation |
|---|---|---|
| Weight | High | Choose lightweight materials like aluminum for better handling and portability |
| Mounting Security | Very High | Ensure sturdy mounting hardware; consider quick-release systems for convenience |
| Fuel Compatibility | Medium | Confirm compatibility with ethanol-blended fuels if applicable |
| Environmental Resistance | High | Opt for UV-resistant coatings and corrosion-proof finishes |
Maintenance Best Practices
Regular maintenance ensures your spare gas tank remains functional and safe throughout its service life. Here are key practices every rider should follow:
Important: Never use a damaged or compromised spare gas tank. Even minor leaks or cracks can pose serious fire hazards. If you notice any issues during inspection, stop using the tank immediately and replace it with a certified unit.
How to Choose a Motorcycle Spare Gas Tank
Selecting the right spare gas tank for your motorcycle involves evaluating several important factors that affect performance, safety, and aesthetics. A well-chosen gas tank ensures reliable fuel supply, complements your bike's design, and meets practical needs based on your riding style and environment.
Riding Style and Purpose
The type of riding you do significantly influences the ideal size and capacity of your spare gas tank. Long-distance touring riders benefit from larger tanks that reduce the frequency of refueling stops, while off-road enthusiasts often prefer lightweight tanks that minimize bulk and improve maneuverability.
- Touring riders: Opt for high-capacity tanks (20L+)
- Commuters: Mid-sized tanks (12–18L) offer a good balance
- Off-road riders: Lightweight, compact tanks (8–12L)
Pro tip: Consider carrying range versus weight trade-offs when selecting capacity
Compatibility with Your Motorcycle
It’s crucial to ensure the spare gas tank is fully compatible with your specific motorcycle make and model. This includes matching mounting points, fuel lines, venting systems, and overall dimensions. Improper fitment can lead to leaks, instability, or even dangerous riding conditions.
- Measure existing mounting points and compare with new tank specs
- Check for OEM compatibility or custom fit options
- Verify fuel cap location and vent system alignment
Important: Always test fit before permanent installation
Material Selection
Different materials offer distinct advantages and disadvantages in terms of durability, weight, and maintenance. Choosing the right material depends on your priorities—whether it's strength, lightness, or cost-effectiveness.
- Steel: Extremely durable but heavier; excellent for long-term use
- Aluminum: Lighter than steel, corrosion-resistant, but less impact-resistant
- Plastic (Polyethylene): Very lightweight, flexible, but prone to scratches and UV degradation over time
Durability note: Steel tanks are more dent-resistant but susceptible to rust if not properly coated
Tank Capacity and Fuel Efficiency
Fuel capacity directly affects how far you can travel between fill-ups. However, increasing capacity also increases weight, which impacts handling, acceleration, and braking efficiency. Finding the right balance is key depending on your typical riding routes.
- City commuting: 8–12L is usually sufficient
- Highway cruising: 14–18L provides extended range
- Adventure/touring: 20L+ for remote area travel
Fuel economy tip: Heavier tanks may slightly increase fuel consumption due to added weight
Design and Aesthetic Appeal
The gas tank contributes significantly to the motorcycle’s visual identity. Whether you're restoring a classic bike or customizing a modern one, the tank should align with your aesthetic vision and complement other components like the fairings, seat, and paint scheme.
- Stock replacement: Match original design and color scheme
- Custom builds: Choose from a wide variety of shapes, colors, and graphics
- Vintage restorations: Reproduction tanks with period-accurate details
Design consideration: Some custom tanks may require modifications to wiring or frame
Emissions Compliance and Safety Standards
In many regions, especially urban areas, motorcycles must comply with emissions regulations regarding fuel evaporation and vapor containment. Using a non-compliant tank can result in fines or registration issues, so always verify local laws before purchasing.
- Look for CARB-certified tanks in California and similar regions
- Ensure proper venting and sealing mechanisms
- Check for crash resistance ratings where applicable
Legal note: Non-compliant tanks may void insurance coverage in some cases
Budgeting Tip: While price shouldn’t be the only factor, it’s wise to invest in quality without overspending. High-end tanks may last longer and perform better, but budget-friendly options can still offer good value if they meet your functional needs and fit well.
| Purpose | Recommended Material | Capacity Range | Key Benefits |
|---|---|---|---|
| Street commuting | Steel or Aluminum | 12–16L | Durability + moderate weight |
| Long-distance touring | Steel | 18–22L | Extended range + reliability |
| Off-road/enduro | Aluminum or Plastic | 8–12L | Lightweight + impact resistance |
| Custom build | Steel or Fiberglass | Customizable | Stylish + unique appearance |
DIY Guide to Replacing a Motorcycle Spare Gas Tank
Replacing a motorcycle spare gas tank is a moderately challenging but rewarding DIY task that can improve the performance and aesthetics of your bike. This guide provides detailed instructions, safety tips, and best practices to help you complete the job safely and efficiently.
Safety Warning: Gasoline is highly flammable and emits dangerous vapors. Always work in a well-ventilated area away from open flames or sparks. Wear protective gloves and eyewear during the process.
Step-by-Step Replacement Process
- Preparation and Planning
- Verify that the replacement gas tank is compatible with your motorcycle model and year
- Gather essential tools: wrench set, screwdrivers, fuel line disconnect tool, rags, and a siphon pump
- Choose a clean, well-lit, and well-ventilated workspace
- Take photos of the existing setup for reference during reassembly
- Ensure the motorcycle is stable using a center stand or wheel chocks
- Drain the Fuel Safely
- Turn off the fuel valve (if equipped) and allow the engine to cool down completely
- Place a fuel-safe container beneath the fuel line to catch any residual gasoline
- Use a siphon pump to extract as much fuel as possible from the tank
- Disconnect the fuel line carefully and drain any remaining fuel into the container
- Properly store or dispose of the fuel according to local regulations
- Disconnect Accessories and Components
- Unplug all electrical connections such as fuel gauge sensors or fuel pump relays
- Remove vent hoses, fuel lines, and any vacuum lines connected to the tank
- Label each connection point using masking tape and a marker for easier reinstallation
- Detach accessories like tank bags, GPS mounts, or phone holders
- If applicable, remove side panels or fairings obstructing access to the tank mounting hardware
- Remove the Old Gas Tank
- Locate and loosen the bolts or straps securing the tank to the motorcycle frame
- Support the tank with one hand while removing the last bolt to prevent it from falling
- Lift the tank straight up and place it on a clean surface
- Clean the mounting area and inspect for damage or corrosion before installing the new tank
- Install the New Gas Tank
- Position the new tank over the mounting points, ensuring proper alignment
- Secure the tank using the original bolts or new ones if provided with the replacement
- Tighten fasteners to the manufacturer's recommended torque specifications
- Reconnect fuel lines, vent hoses, and electrical connectors following your labels
- Double-check all connections for tightness and correct routing
- Check for Leaks and Test Operation
- Turn the ignition key to the “ON” position (without starting the engine) to pressurize the fuel system
- Visually inspect all connections for signs of leakage
- Sniff near connections for any gasoline odor indicating a leak
- If leaks are detected, turn off the ignition and tighten fittings or replace damaged components
- Reinstall Accessories and Final Check
- Reattach any accessories removed earlier, such as tank bags or electronic mounts
- Replace side panels or fairings if they were removed
- Start the engine and let it idle while monitoring for unusual behavior
- Check fuel flow and ensure the fuel gauge is functioning properly
- Perform a short test ride to confirm everything operates smoothly
| Phase | Key Actions | Potential Issues | Recommended Tools |
|---|---|---|---|
| Preparation | Compatibility check, workspace setup, documentation | Mismatched tank, missing tools, inadequate ventilation | Rags, camera, fuel-safe container |
| Fuel Drainage | Siphoning fuel, disconnecting lines | Spills, fume accumulation, incomplete drainage | Siphon pump, fuel line pliers |
| Disconnection | Removing accessories, labeling connections | Misplaced parts, incorrect labeling | Markers, zip ties, screwdriver set |
| Installation | Mounting the new tank, reconnecting systems | Improper alignment, loose connections | Socket set, torque wrench |
| Testing | Leak checks, system tests, final inspection | Undetected leaks, faulty readings | Flashlight, multimeter (for sensors) |
Expert Tip: Before installation, consider cleaning or replacing the fuel filter and inspecting the fuel pump if your motorcycle has one. Also, apply dielectric grease to electrical connections to protect against moisture and corrosion.
Motorcycle Gas Tank FAQs – Expert Guidance for Optimal Performance
A1: Generally, it is not advisable to switch to a different gas type than what your motorcycle is designed for. Motorcycle fuel systems are calibrated specifically for certain types of fuel—most commonly unleaded gasoline with octane ratings between 87 and 93. Switching to alternative fuels like ethanol blends (E10, E15), diesel, or racing fuels without proper modifications can lead to:
- Potential damage to the carburetor, fuel pump, or fuel injection system
- Reduced engine performance and fuel efficiency
- Increased risk of corrosion in the gas tank and fuel lines
- Voiding of manufacturer warranties
If you're considering using an alternative fuel, consult a certified mechanic or refer to your owner’s manual for compatibility details and necessary modifications.
A2: Yes, installing a larger gas tank on your motorcycle is possible and often done by riders who enjoy long-distance touring or ride in remote areas. However, several important considerations should be made before proceeding:
- Fitment: Ensure the new tank is compatible with your bike's frame and doesn’t interfere with other components like the seat, exhaust, or suspension.
- Weight distribution: A larger tank will add weight, potentially affecting handling and balance, especially when full.
- Fuel system compatibility: Check if your fuel pump and lines can handle the increased capacity without overheating or starving at high flow rates.
- Legal compliance: In some regions, modifying the fuel system may require re-certification or inspection to meet emissions standards.
Always consult a qualified mechanic or experienced custom builder to ensure safe and effective installation that maintains the integrity of your motorcycle’s design.
A3: While there is no universally fixed schedule for cleaning a motorcycle gas tank, regular maintenance intervals and riding conditions play a significant role. As a general guideline:
- Clean the tank every 2–3 years if used regularly and stored properly
- Inspect and clean immediately if signs of contamination appear
- Consider cleaning after long-term storage (over 6 months)
Cleaning helps prevent sediment buildup, rust formation, and fuel system blockages that can affect engine performance. It's also recommended to perform a thorough cleaning before storing the motorcycle for winter or extended periods.
A4: Detecting early signs of gas tank damage is crucial for safety and preventing costly repairs. Common indicators include:
- Visible leaks: Drips or puddles of fuel under the motorcycle when parked
- Rust or corrosion: Especially common in older steel tanks exposed to moisture
- Bubbles or swelling: Often seen in plastic tanks due to chemical degradation or overfilling
- Strong gasoline odor: Persistent smell even when the engine is off
- Engine performance issues: Stalling, hesitation, or rough idling caused by fuel delivery problems
- Wetness around the tank area: Could indicate slow leaks or venting problems
If any of these symptoms are present, have the tank inspected by a professional as soon as possible. Continuing to operate a motorcycle with a compromised fuel system poses serious fire and mechanical risks.