Gas leak 07 919 - Wrist Twisters
 
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post #1 of 14 Old 08-30-2015, 02:21 PM Thread Starter
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Gas leak 07 919

Hey guys, I am in need of your help here! Came home from work, bike was sitting in the shade covered with a waterproof cover. I noticed a puddle under the bike and turns out it is gas. Filled up the bike a couple of days prior to this and only rode 65 miles on a full tank. The rest is gone!!! gas light came on when I turned the key and the bike started up fine but the leak is still there under the bike. Please help, what can it be?

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post #2 of 14 Old 08-30-2015, 03:32 PM
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Your best bet is to lift the tank and do a visual inspection. You may have had a line come loose or the fuel pressure regulator could have went bad.

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post #3 of 14 Old 08-30-2015, 03:34 PM
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Oh boy....

I've been here too many times to count. I feel your pain.

To start, make sure all of your vent/drain hoses are not clogged and pressure moves freely. Secondly, check to make sure your fuel lights are tightened down appropriately as called for in the manual. Thirdly, check to make sure your fuel pump bolts are torqued properly (too much can cause too many issues!) and that your fuel pump gasket is sealing good. Fourthly, check to make sure your gas tank doesn't have any cracks. You can do this by doing a visual inspection including on the underside.

Did your gas tank expand/contract to the point where the gas tank is warped? I'm sure others will chime in as well.

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post #4 of 14 Old 08-30-2015, 03:39 PM Thread Starter
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Thank you for the responses guys. What is a fuel pressure regulator look like? I lifted the tank and looked underneath. All the hoses seem to be connected and the gas seems to be coming from the round metal cap right underneath the gas tank in the center. It has a rubber gasket under the cap and I think that's what went bad.

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post #5 of 14 Old 08-30-2015, 03:45 PM Thread Starter
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This is what I'm talking about
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post #6 of 14 Old 08-30-2015, 04:10 PM Thread Starter
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I have figured it out guys. All the gaskets and hoses are good. The underneath of the gas tank has a stress fracture/pinch that has gas leaking out of. How do I get this fixed? Please help, I am in San Marcos, north San Diego county. Any help is appreciated!

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post #7 of 14 Old 08-30-2015, 04:54 PM
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Easiest is new tank time otherwise remove it and find somebody brave enough to braze it but then you may have paint issues anyways good luck

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post #8 of 14 Old 08-30-2015, 05:07 PM
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Quote:
Originally Posted by Makar919 View Post
I have figured it out guys. All the gaskets and hoses are good. The underneath of the gas tank has a stress fracture/pinch that has gas leaking out of. How do I get this fixed? Please help, I am in San Marcos, north San Diego county. Any help is appreciated!
Eww it sounds like you need a new tank or have the old one welded up.

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post #9 of 14 Old 08-30-2015, 05:17 PM
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Oops. Shity deal. You could try letting it dry and smear on some JB weld.

Spoiler:

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post #10 of 14 Old 08-30-2015, 05:51 PM
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Looks like you had a vent issue that resulted in pressure building up and the gas tank expanded/contracted which caused the fracture/pinch. It looks like it is in an area that is easily welded.

Drain your tank completely, cork up both openings and pour in a diluted mix of rubbing alcohol. 2:1 works well. Swish it around a bunch of times, open the top and let it sit for a few hours, cork it back up and swish it around a bunch, empty it out, let it air out for a couple of days and see if you can smell any fuel. If you can still smell fuel, repeat the process. When you for sure cannot smell any fuel fumes, hunt down a welding shop who can weld it up for you. Should cost no more than $60-80. The hard part will be finding someone who's willing to take a crack at it as people freak out as soon as they hear "gas tank" and "weld" in the same sentence.

The other option is to just buy another tank.

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post #11 of 14 Old 08-31-2015, 05:55 PM
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Best bet is to buy a new one, then sell the old on eBay to someone who wants to attempt the repair. You might recoup some of your costs of a new tank.

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post #12 of 14 Old 09-02-2015, 07:44 AM
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Frankly, it is easy to weld on a fuel tank without a long drawn out flushing process. All you (or the welder doing the work) need is a source of inert gas to purge the tank of oxygen. No oxygen, no combustion. I have done this many times without a single fuel grenade going off, even with fuel still in the tank. Commonly, I go to a party supply and get the smallest tank of helium they have. It works like a charm. Of course you will want to drain all remaining fuel out, but given the huge hole left when the fuel pump is removed that's a cinch.

Naturally the welding will burn out any coating on the inside of the tank, and if you can get to the location of the crack through the fuel pump hole I'd advise removing any coating to allow proper penetration of the weld.

If you want to epoxy up the crack I would not advise using JB weld: it will be degraded by continuous contact with gasoline. A more permanent solution is Marine Tex epoxy, available at most Marine / boating businesses. It is specifically formulated for resistance to volatiles, and in fact I have patched tanks with it and forgotten all about it for more than ten years without a problem.

Good luck.

Rob

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post #13 of 14 Old 09-02-2015, 03:56 PM
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I agree with you 100% Rob. The problem is finding someone who is willing to even weld a gas tank lol. Why can't you just travel around the country and do all the amazing work for us that you do? Lol.

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post #14 of 14 Old 09-02-2015, 04:53 PM
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I'm a welder by trade and would be willing we are way too far apart though

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