I Need Help, My Bike Hates Me... - Wrist Twisters
 
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post #1 of 26 Old 09-26-2006, 02:13 PM Thread Starter
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I Need Help, My Bike Hates Me...

Alright guys I need you're help as my wonderful "extended warranty" doesn't cover what happened last night...

'05 919

I'm ridin' home from the gym and I notice a distinct gasoline smell coming from my bike at the stoplights along the way and the closer I got to home the more my rpm(s) started to drop and I was barely keeping the bike running at those stop lights. So I figured I was losing fuel pressure perhaps because I was out of gas (even though I knew I wasn't because I had filled up two days prior and only gone to SLC and back.) So I swing a mile past my house and pull into the Chevron and get off my bike to see literally, a piss stream's worth of gas traveling from directly under my tank all over my bike down onto the ground. In a matter of 3-4 minutes I was, out of gas. I pulled the tank off and from what I can wager the leak was/is coming from my sending unit and it's just not sealed properly. But I can't tell, is there a better way to diagnosis the leak than pouring another half gallon of gas in there and making a mess again? (I risked it with such a half a gallon and rode it home, quickly but still couldn't tell) My fuel lines and returning lines look good, but again, I can't be sure...

Guys I gotta get this fixed and soon. There are only a few more weeks of riding left here in Utah and my bike needs to be riden! Any thoughts or help would be greatly appreciated!

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post #2 of 26 Old 09-26-2006, 02:28 PM
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Should be pretty easy to pinpoint the problem. Loosen the fuel tank mounting bolt, slide the tank backwards, and prop it up with a block of wood. Pour some gas in the tank and look for the leak.

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post #3 of 26 Old 09-26-2006, 02:36 PM Thread Starter
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Mike makes everything sound so easy...

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post #4 of 26 Old 09-26-2006, 02:42 PM
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And don't smoke during this procedure Oh wait, you were coming from the gym so probably not a smoker!

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post #5 of 26 Old 09-26-2006, 02:44 PM
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your extended warranty may very well cover this if a seam separated or like problem that you didn't cause.

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post #6 of 26 Old 09-26-2006, 02:52 PM
 
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i cant do much but its true, loosin' up the tank and checkin' the hoses is really quite simple.

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post #7 of 26 Old 09-26-2006, 02:55 PM
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Mmmmajorrrr Nick-nuts roasting on an open firrrrre,

Jack Frost nipping at your nose.....

Seriously tho, sounds like the gasket that seals the fuel pump under the tank is leaking. After replacing mine when I replaced the tank I'm surprised it isn't a more common problem.

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post #8 of 26 Old 09-26-2006, 03:09 PM Thread Starter
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It's a (explitive) hole in the tank!!!! How on Earth could that happen??? Its about the size of a ball point pen tip, Razorbike, you know all about that measurement scale...what do I do now? I already went out to my bike last week and found a mysterious tiny dent in the tank. I thought it was the handle bars that had perhaps crashed into it but the bars and the dent don't line up, they are close but not that close! UGH!!!!!!! My factory warranty went up not three weeks ago...this sucks. Could I weld it shut?

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post #9 of 26 Old 09-26-2006, 03:20 PM
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That sucks... Possible vandalism??? In any event J-B Weld is your friend. Make sure the area is totally clean and dry before applying.

EDIT: Factory warrenty would not have helped you. If possible, could you take a pic of that hole and post it?

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post #10 of 26 Old 09-26-2006, 03:27 PM
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I had a similar hole in the radiator of my NSR250 and a little tab of JB-Weld fixed me up great.

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post #11 of 26 Old 09-26-2006, 03:29 PM
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Quote:
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I had a similar hole in the radiator of my NSR250 and a little tab of JB-Weld fixed me up great.
Is there a echo to this post???

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post #12 of 26 Old 09-26-2006, 03:43 PM Thread Starter
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I'll try and post a pic...without getting gas all over my camera

J-B Weld, am I gonna have to order that online or can I get it at home depot?

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post #13 of 26 Old 09-26-2006, 03:45 PM
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Quote:
Originally Posted by MajorNickmo View Post
I'll try and post a pic...without getting gas all over my camera

J-B Weld, am I gonna have to order that online or can I get it at home depot?
Home Depot, any local auto parts store, or hardware store should carry this product.

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post #14 of 26 Old 09-26-2006, 03:52 PM
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There is still something fishy going on here. Lets assume your tank was vandalized and a hole was poked in it. It seems to me you should have noticed or at least smelled gas immediately. What am I missing???

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post #15 of 26 Old 09-26-2006, 03:55 PM
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a peculiar problem this is.
if it were a seam or a manufacturing flaw maybe you'd have a warranty shot but not with a hole. even road debris would have a problem making a hole in the tank. made any enemies lately?

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post #16 of 26 Old 09-26-2006, 04:09 PM Thread Starter
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The hole is on the underside of the tank in the middle of the seam, right hand side of the tank. I can't get a good picture of it, it's impossible without someone else holding the tank up high enough. The dent on the top is minor and just needs some touch up paint and you'll never even see it without really looking.

Question now is, what is the best way to take my tank off--completely off--what steps should I follow, so I can J-B weld the hole???

I know everyone in the neighborhood and 2 out of every 3 households has a bike or a quad. Nothin' but good wholesome families here. No enemies.

Could the previous owner have put the tank back on wrong and I've just been riding it screwy for 3 months and the seam just got bumped the wrong way??? It's a long shot I know.

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post #17 of 26 Old 09-26-2006, 07:52 PM
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MajorNickmo,

I live in the SLC area and have a MIG welder. If we can get all the fumes out of the tank I will weld if for you. JB Weld can only hold it for so long. Gasoline will always win over the bonding battle. PM me if you are interested in my help.

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post #18 of 26 Old 09-26-2006, 08:13 PM
 
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Quote:
Originally Posted by MajorNickmo View Post
The hole is on the underside of the tank in the middle of the seam
Not likely vandalism on the underside of the tank! A hole in the seam sounds like a defect to me. This could actually be something the factory warranty would cover if it were in effect. Not sure if the extended warranty would cover it, though-- it depends on which extended warranty you have. Take pics before you do anything to fix it.

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post #19 of 26 Old 09-26-2006, 08:30 PM
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MajorNickmo,

I live in the SLC area and have a MIG welder. If we can get all the fumes out of the tank I will weld if for you. JB Weld can only hold it for so long. Gasoline will always win over the bonding battle. PM me if you are interested in my help.
Take the tank off of the bike. You can fill it with h2o and it will be safe for welding. That will take care of the fumes.

post #20 of 26 Old 09-27-2006, 11:16 AM Thread Starter
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Motocycho, PM sent, Thanks man! WT Rocks!

Since my tank is completely out of gas (well almost, if you put it on the center stand some more comes out) Are there any precautions I should take when removing all the fuel lines from it? Do I need to clamp off the hoses while the tank is gone? What is the best way to remove those hoses? Just remove the C clamps and pull? Or should I fill it with water now and then remove it...
No but seriously, I dont need to do any more damage here.

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post #21 of 26 Old 09-27-2006, 11:30 AM
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For the tight hoses I squirt a little Break Away in there and they slide out much easier. Works even better if you can pry the hose up a little then get that red straw in there a little.

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post #22 of 26 Old 09-27-2006, 11:42 AM
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Even if it is out of warranty, what have you got to lose by going to the dealer and seeing if there is something Honda will do for you. If it's leaking at the seam, that's clearly a factory defect, and I would think Honda would make it right.

If it is leaking at the seam and Honda won't step in, I'd bite the bullet and replace it and sell the old one on E-Bay.

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post #23 of 26 Old 09-27-2006, 03:20 PM
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Quote:
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If it is leaking at the seam and Honda won't step in, I'd bite the bullet and replace it and sell the old one on E-Bay.
See, there you go, right there. Sniper volunteered to replace it for you and sell the old one. Isn't this a great place?

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post #24 of 26 Old 09-27-2006, 07:32 PM Thread Starter
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Wow, this forum is amazing Thanks Sniper! A new tank is only $454! What a pal!.

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post #25 of 26 Old 09-28-2006, 09:38 AM
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I J-B welded the gastank on my lawnmower in 1982, it's been fine since. Originally this was to be a temporary fix until the new tank showed up but it was back-ordered for 3 months. It eventually it turned into a long term science project to see how long it would last. I have rebuilt the engine twice in the last 24 years but never bothered to install the new tank. J-B WELD RULES!

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post #26 of 26 Old 09-28-2006, 09:40 AM
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Quote:
Originally Posted by hasbeenracer View Post
I J-B welded the gastank on my lawnmower in 1982, it's been fine since. Originally this was to be a temporary fix until the new tank showed up but it was back-ordered for 3 months. It eventually it turned into a long term science project to see how long it would last. I have rebuilt the engine twice in the last 24 years but never bothered to install the new tank. J-B WELD RULES!
Truth! My dad cracked open the case on his DRZ400 out in Colorado, JB Weld fixed it that evening and he's used it for two seasons of off road riding since problem free before selling it as is.

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