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Question on ethanol fuel

jacko'Cubs

Member
Joined
Nov 19, 2025
Messages
6
I have noticed that the plastic tanks on older Monsters tend to swell if they sit with cheap gas for too long. It makes getting the tank back on the frame a massive chore. I try to stick to ethanol free fuel but it is getting harder to find at the pump. What are you doing to protect your tank from expanding or have you switched to a coating? Any help will be appreciated. Thanks!
 
I have noticed that the plastic tanks on older Monsters tend to swell if they sit with cheap gas for too long. It makes getting the tank back on the frame a massive chore. I try to stick to ethanol free fuel but it is getting harder to find at the pump. What are you doing to protect your tank from expanding or have you switched to a coating? Any help will be appreciated. Thanks!

I have a tank that is so swollen I have to use a literal pry bar to get it onto the mounts. It's incredibly frustrating that a premium brand would use materials that react this way to standard pump gas. I am looking at getting an aluminum tank.
 
Star Tron fuel additive has been a life saver for my plastic tank. I add a little bit every time I fill up and I have not noticed any more swelling in over two years. Cheap way to prevent a very expensive problem.
 
Does the swelling eventually stop or does the tank just keep growing? I am worried that eventually the seat will not fit properly or the mounting bolts will just snap off. It seems like a design flaw that we all just accepted. Makes me think otherwise now.
 
I have noticed that the plastic tanks on older Monsters tend to swell if they sit with cheap gas for too long. It makes getting the tank back on the frame a massive chore. I try to stick to ethanol free fuel but it is getting harder to find at the pump. What are you doing to protect your tank from expanding or have you switched to a coating? Any help will be appreciated. Thanks!

I make a point to ride twenty miles out of my way to find the one station that sells ethanol free fuel. My bike runs much smoother and I do not have to worry about the tank or the fuel lines degrading. It is worth the extra trip I'd say. But that;s just me.
 
I had my tank coated with Caswell a few years ago and it solved the problem. It creates a barrier that the ethanol cannot get through so the plastic stays stable. You just have to be very careful with the prep work before you pour it in.
 
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