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Discussion Starter · #1 ·
Morning all,

Background: recently I'd been smelling gas while riding, just a whiff here and there. Took a few looks but nothing seemed wrong. Then last week, I was changing the oil and when I started her up, I noticed a steady stream of gas leaking out from under the fuel tank and running down the engine. I couldn't tell the source, but it clearly was NOT the fuel line/attachment point - it was from up under the middle of the tank.

I pulled the tank off (changing plugs anyway) drained the fuel, and checked out the fuel level gauge, since that seems to be the only place the leak could be coming from. I unscrewed the 4 screws, and although there was some rust flakes around it, the O-ring seemed perfectly fine. I screwed the fuel level gauge stuff back on, started it up, and no leak. So I thought it was good to go.

Unfortunately, yesterday while starting the bike, the gas leak was back and badder than ever. Especially bad when I had the choke out to start the bike, but still flowing pretty good when I had the choke in.

I'm looking for ideas - any place this leak could be coming from that I'm missing? Should I replace that fuel gauge O-ring even though it looks fine? Should I use some sort of sealent over the O-ring? Or maybe I'm not torquing the screws appropriately (didn't see a torque guide in the pink book)?

Thanks for any ideas - not riding the bike as is but hoping to soon in the 100 degree weather we have coming up...
 

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Unfortunately, yesterday while starting the bike, the gas leak was back and badder than ever. Especially bad when I had the choke out to start the bike, but still flowing pretty good when I had the choke in.
You need to check the fuel line thoroughly an double check your work on the sender plate re-install.
 

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Discussion Starter · #3 ·
You need to check the fuel line thoroughly an double check your work on the sender plate re-install.
Thanks for the reply - is the sender plate the 4-screw circle that holds the fuel level gauge? I'm pretty sure the fuel line is not the problem as I replaced it recently, and I can actually see the fuel coming from under the tank when it's leaking. Any ideas on sealing the "sender plate"?
 

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If you are 100% sure the gauge attachment is not leaking, then I would look at the fuel line running from the fuel pump to the carb. Remember the old saying "Water Travels". Fuel does too. If that line is damaged, fuel can shoot up on the bottom of the tank and make it look like the tank is leaking.

Just a guess!

Ride Safe.
 

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Thanks for the reply - is the sender plate the 4-screw circle that holds the fuel level gauge? I'm pretty sure the fuel line is not the problem as I replaced it recently, and I can actually see the fuel coming from under the tank when it's leaking. Any ideas on sealing the "sender plate"?
yeah.

You replaced the whole fuel line tank to fuel pump to carb?

Any fuel resistant gasket sealer should work.
 

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Discussion Starter · #6 ·
2nd fuel line

yeah.

You replaced the whole fuel line tank to fuel pump to carb?

Any fuel resistant gasket sealer should work.
Seems obvious now, but I didn't realize there was a second line, from the pump to the carb. I only replaced the line from the tank to the pump. Is this second fuel line the same diameter? Do you know the length off-hand? I'll replace that even if it's not leaking! As for a fuel-resistant gasket sealer, never bought one - but hopefully not that hard to find. Thanks!
 

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Looks like we owe you a response. The fiche shows the following measurement: HOSE,4.5X8.5,6X. For that to be the hose I know is there, the first number has to be millimeters and oddly enough the second would be inches. I think you can just get some line at the auto parts store. But you have to make sure it is heat resistant.

Hope that helps.

Ride Safe!
 
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Seems obvious now, but I didn't realize there was a second line, from the pump to the carb. I only replaced the line from the tank to the pump. Is this second fuel line the same diameter? Do you know the length off-hand? I'll replace that even if it's not leaking! As for a fuel-resistant gasket sealer, never bought one - but hopefully not that hard to find. Thanks!
Easy to find.
 

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I'm having a similar problem. It only leaks when starting (and running?), not when it's just sitting and turned off. When I use a flashlight and look up toward the carb, it appears that the fuel is dripping off the carburetor. I plan to remove the tank, replace the hose from tank to fuel pump with one long enough to have the tank on the work bench, then crank and start. Hopefully, the source should be obvious at that point.
 

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I'm having a similar problem. It only leaks when starting (and running?), not when it's just sitting and turned off. When I use a flashlight and look up toward the carb, it appears that the fuel is dripping off the carburetor. I plan to remove the tank, replace the hose from tank to fuel pump with one long enough to have the tank on the work bench, then crank and start. Hopefully, the source should be obvious at that point.
I also had a similar problem, not bad at all, and like you when I would look up under the tank at the bottom of the carb it was wet with fuel. It was not the line from the fuel pump to the carb, mine was the gasket on the float bowl. I was jetting the carb, and the reason that I was taking everything apart anyway. Mine is a 2004, and when I took the float bowl off the gasket had obvious signs of leakage, there is also a round O ring from the accelerator pump on the carb which is on the float bowl as well. When I re-jetted I replaced all those gaskets and O rings and now no leak. So check your float bowl gasket and your accelerator pump O ring for leaking. Of course you will have to take the carb out of the bike to do this, so make sure it is NOT a fuel line first.

I had previously replaced both sections of gas line from the tank to the pump, and pump to carb with new, and had also replaced all the vacuum lines as well. And still had the small leak.

HTH
Marty
 

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Marty - Thanks for you input. When I get a chance to work on it, I'll post my findings. I am leaning toward carb gaskets as well. Mine is an '04 too. I got it used so I don't know if the carb was ever disassembled.
 

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Marty - Thanks for you input. When I get a chance to work on it, I'll post my findings. I am leaning toward carb gaskets as well. Mine is an '04 too. I got it used so I don't know if the carb was ever disassembled.
You are very welcome, now let me save you some money, you can get what they call a rebuild kit, which has the O ring and gaskets and a new float needle all in one package, unlike what I did before I realized it. I purchased each individual O ring and gasket and float needle separate. Even at that the cost was not bad, but I could have gotten it all in one kit. DUH LOL. They have them on Ebay. The float bowl gasket is actually what I would call a O ring but shaped to the groove in the bowl. It is not a standard flat gasket. Also be very careful of carb cleaner and leaving it too long, the rubber vacuum diaphragm in the needle cover does not like it at all as it is very thin. I began the cleaning process with the carb already off the bike, so it didn't have the cleaner on it long. When I got it all cleaned off, I took some silicone spray and coated the diaphragm and rubbed it in with my fingers, it conditioned it and made it like new.

HTH
Marty
 
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