Boom Vader Gas Tank Gasket ISN’T Leaking? :(

Well, reading the headline, you might be wondering why the sad face figuring out the gasket isn’t the problem with my Boom Vader’s leaking gas tank. I found out the problem is worse, and the solutions are more complicated or nonexistent.

Okay, I removed the Boom Vader’s gas tank after draining the gasoline into an approved container ( How I Drained My Motorcycle Gas Tank (My Carbureted Grom Clone) ). Couldn’t believe how many screws and bolts needed to be removed to take off a Grom Clones fairings.  

The Boom Vader seat came off as expected, and the end part of the plastic tail was removed to get the side panels off, but not before taking off the front panel. Once these were removed, there were additional plastics on the gas tank.  

If you don’t have a magnetic parts tray, as I do, I recommend you get one. Check my Must Have Tools page.

Also, zip lock bags are your friends too. Just get a permanent marker to label your bags.

Once the gas tank was off, I could see fuel around the gasket that led to the gas level sensor. The nuts holding the level sensor in place and compressing the gasket weren’t really ‘tight’ and, being a Chonda, had no thread locker. So I examined the site and tightened the gasket to white-knuckle tight, and refilled the gas tank to test my work.  

Boom Vader gas tank level sender unit.
Gas leak was under the level sender plate, figured it was the gasket. NOT!

FYI, to prevent problems, I took the gas fuel line that feeds the carburetor and connected the end to the gas tanks’ vent tube. Prevented spilling when leak testing.

After just a little gas, the gas dripping started again. My gasket tightening operations didn’t work.

Re-drained the gas tank and disassembled the tank-level sender unit. Fairly easy. Remember, there was no thread locker. Geez…

Boom Vader gas tank on garage floor.
Sender unit off gas tank, gasket present, and no cracks noted.

I looked at the gasket and saw no cuts, no cracks, no holes. The mating surfaces of the gas tank and the sender unit weren’t warped or dented. Figured the gasket wasn’t all that great quality. It didn’t feel ‘squishy’ to me, so I would replace this. The Boom Vader was still under warranty.

Boom Vader Motorcycle gas tank gasket.
The gasket, the back ring, was intact, just didn’t feel supple and looked like an easy source of the leak

Contacted The Boom Vader Seller.

To speed up the process, I contacted my Boom Vader’s seller. I will later do a review of the sale experience, so not going to reveal names now. I asked not for a replacement. I didn’t want a Grom Clone gas tank gasket. I want an aftermarket better version. Before I got a response, I found the true problem.

So Where Was The Grom Clone Gas Tank Really Leaking From?

The next morning, I looked at the tank early the morning and opened my garage car door. The garage still had a strong smell of gasoline, and I wanted to air it out. The Sun was up and shining right into my garage.  

Warning, what did I wouldn’t recommend? I was wearing my safety glasses, and the tank was bone dry sitting on my garage floor overnight, but the risks of injury are real. Just documenting what I did, not what I recommend.

On a hunch, I took the gas tank and plugged the bottom with a rag, blocking all light through the gas tank level sensor hole. I held the tank up to the Sun and looked through the gas filler hole. Letting my eye adjust, I could see pinholes in the metal. NO!!!!!!    

I was concerned about the rust I saw in the Boom Vader’s gas tank ( Boom Vader Assembly Problems & Concerns ), but this wasn’t that.

It seems where the bolts were attached to the bottom of the gas tank, a weld or two popped free, creating a tiny pinhole. That got worse with time. I noticed a gas smell in the beginning, before the visible leaks, but this was a manufacturing defect.

Boom Vader gas tank pin hole leak.  Spot weld failure.
After I saw Sunlight through pin hole, went looking for source of light. This is what I found.

Contacted Boom Vader Seller, Again.

The seller got back to me, I verified the information he gave, and the story is sad. Many of the Grom Clones have had a point of failure with their gas tanks. The spot welds on the bottom of the gas tank that hold the bolts for clamping the gas tank level sensor down were frequently failing.

Leaking Grom Clone gas tanks is a frequent problem. I was fair with the seller. If this happens too often, I want a non-Grom-Clone gas tank. He commented that he couldn’t get me a Grom Clone gas tank right now since they are all out. But if I felt repairing the current tank was more reliable, the seller stated he’s heard people taking the gas tanks to radiator repair shops for repairs and reinforcements.

A radiator repair shop was a good idea, but I wanted to weigh out my options. With no immediate new gas tank replacement and no experience with radiator repair shops, I started to do research.  

So, Curious, How Much Is A Boom Vader Gas Tank?

Boom Vader uses typical Grom Clone gas tanks, and I didn’t find anyone that had one in stock but found prices were well over $100. DIY is looking better and better. I could wait for a replacement Grom Clone tank from the warranty problem, but I figure I would get another dud, so soldiering on.

How Much Does It Cost To Repair A Motorcycle Gas Tank?

Without taking my Boom Vader’s tank around to motorcycle gas tank repair service shops, I only got a few guesstimates from online sources. About $100 seems to be the range I am looking at if someone could repair my tank for me. Again, DIY is looking even better.

As a Chonda-owner, we do DIY, and I like DIY solutions.

So I Went To FB Groups For DIY Suggestions.

Interesting stuff you find doing random searches on the web, but I came up with some leaking gas tank solutions.

Can A Motorcycle Gas Tank Be Repaired By Me?

The response was great. I cannot believe how many people have had motorcycle gas tanks that develop pinholes made by rust. Ethanol gas and poor winterizing ( Easy TBR7 Winterize Motorcycle Checklist ) are problems the sources of all these suggestions.

I was told I could do my own motorcycle gas tank sealing with a multi-step gas tank sealing system.

  • 1st step is to clean the inside of the gas tank
  • 2nd step preps the metal for sealing
  • 3rd step is an epoxy coating layer that bonds to the bare tank bare metal.

This motorcycle gas tank sealing system sounded great! Didn’t know there were so many commercial motorcycle gas tank sealer products.

Of course, after reading the cost of the DIY gas tank sealing system, a professional motorcycle gas tank repair service doesn’t look so bad. 😀

My Gas Tank Repair Plans!!!!!!!

With all the questions I was given, I have a plan with backup plan and a backup backup plan.

Plan A: Spot fixes the pinhole leaks.

I can see where they are in the gas tank, and the metal feels solid enough. Simply plugging the holes should suffice.  

What Am I Trying? J-B Weld. This stuff has a great reputation.

Two part J-B Weld package.
J-B Weld says fuel resistant and over 5,000 pounds strength. Should fix my gas tank.

Follow Up Post: Motorcycle Gas Tank Leak Repair Job.

Plan B: I will try the commercial motorcycle gas tank sealing product.

Figure if it’s designed to do what I want, it should work just that J-B Weld is cheaper and has a good history of fixing so many things cars.

Plan C: Wait for my Boom Vader’s seller to get gas tanks in. After I get a replacement.

Afterwards, I will take it down to a motorcycle gas tank repair service shop. In this case, I believe I should be looking for radiator repair shops in Google now. :/

Plan D: I will get a genuine Honda Grom gas tank.

I was told the early Honda Groms weren’t fuel injected, so an early Grom gas tank will fit today’s carbureted Grom Clone motorcycle. I’m not sure about this. However, if I get down to “Plan D,” I’m desperate.

I wish I had a Plan E, like an aftermarket plastic replacement gas tank, but I haven’t found a drop-in Grom Clone replacement yet. If you know of one, please leave a comment below.

Check back later. I’ll tell you the results. Hope this information and my repair attempts will help other Grom Clone owners with this common gas tank leak problem.

Ride Safe, Ride Fun!

Click To See My Recommended

Boom Vader Gen 2 Upgrades

Picture of me, as a New Motorcyclist.
Just Me…Newly Licensed.

Hi I’m Tom, A New Motorcycle Rider and Blog Author.

I am a new rider(Pa Learners Permit at the end of 2020, and I received a Pa Motorcycle License in 2021 after passing a Motorcycle Safety Course).

I bought my first motorcycle, a TaoTao TBR7, at the beginning of 2021 and have been doing upgrades on that motorcycle since.

I added to my motorcycle collection by buying a Boom Vader Gen 2 in 2022, and that Grom-Clone motorcycle has been upgraded by me as well.

I continue to ride my Boom Vader Gen 2 motorcycle as well as my TaoTao TBR7 dual-sport bike.

Read more on my About Me page.

Fun Fact: I’ve only been on one group ride.

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