Motorcycle Repair: Ninja Fuel Tank Leaking, gas tank repairs, kawasaki ninja

Question
Hello Wayne,

I have a 1993 Kawasaki Ninja EX250.  I purchased it at a government auction and have been giving it a makeover since purchase.  When I filled it with fuel the first time, I found out that the fuel tank was leaking when the cowling bolts through the tank.  There are 2 bolts on both sides that hold the mail cowling on, and it appears that they protrude into and through the tank.  Someone told me that these holes were supposed to be sealed and that someone may have replaced the original bolts with some that were too long, thus puncturing the tank.  Is it supposed to be this way?  I have the factory screws and have replaced the rubber grommet in the cowling and also have tried liquid metal filler and it still leaks.  Any suggestions>

Answer
Tracy,
yes, the holes are supposed to be sealed,
Kawasaki even recalled some later models
because the wrong bolts were used or somebody
at the factory screwed a tap in to clean up
the threads and punctured the tanks.
The fix is find a welder willing to do gas tanks,
maybe a radiator shop or get another tank which
may also be bad unless it's new.  The only other
cheaper fix might be some epoxy that is specially
made for gas tank repairs. Check with auto parts
stores for that one. The only permanent repair
is welding or replacement unfortunately.