Leaking gas tank

Kengray

Kengray

My gas tank is leaking where this piece is attached (please see pic in photo galleery)

I recently installed a PCIII and removed the gas tank to route the PCIII harness. I rode the bike once, about 100 miles and it was not leaking. I rode it a second time yesterday and the leaking started.

The only thing that I can think is that somehow I hit this piece attached to the inside of the tank when removing / installing the tank.
I'm not even sure what the function of this piece is. I'm guessing that it is the fuel level sensor?
I tightened the bolts securing it a little tighter than they were, but didn't want to strip the nuts embedded in the tank. Still leaking. I'm now going to remove it and check the gasket.
Wondering if this has happened to anyone else? Any advice? Thanks, Ken
Ankka

Ankka

Post missing.

Kengray

Kengray

Post missing.

cjc

cjc

Kengray, Yes....you are correct, that is your low fuel light sensor,

This is one for the text books, I have had my fair share with trouble on

cars on these issues, for instance...I had a customer bring me a 96 Q-45

infinity, on the tow truck and cranks but will not start, I find that the fuel

pump is bad, the pump is $590.00 + $180.00 labour, I work alone so I did

not want to remove the tank cos it was in the trunk, so I had managed to

get the pump out after wrastleing it for an hour, put in the new one in and

now I have a fuel leak, so I go into my information on the job.......nissan

states to always put a new o-ring in during installation and be sure to

torque the 6mm screws to 17 in. lbs, I had to redo the job and it worked

but I had to replace the whole tank cos I had overtightened the screws the

first time, fook me, I had to learn the hard way that overtightening the

screws ruined the tank where it seals to the pump housing.

This took me 3 times of dicking with it to figure out that the tank was

damaged. I have not ever seen a sealing product that works on fuel.

( DO NOT OVERTIGHTEN THE SCREWS )


Peace.......joe
cjc

cjc

Post missing.

cjc

cjc

cjc, I would run straight to me dealer if I were in yer shoes, (as long as ye are still in the warranty time frame?).

I hate the smell of raw fuel, or even burned fuel, many critisizums have

been pointed at me, over this smelly issue, but fuel leaks are dangerous

on a bike merely cos of the tight design, you could have a crispy critter for

an SD quicker than you would ever believe,,,,, if the drop or 2 of fuel

manages to make it to the (red hot @ nite)exhuast pipe, then to fumes of

the tank! I too am also curious as to kengray's diagnosis and repair.

Here is the deal? the tank is unhinged on the SD, but KTM puts this

Ridiculous strut/shock unit on the tank to frame on the SD, like you need to

be under there all the time? well,,,,There is very little need to get under there

and the strut has no function except to force you into removing the whole

tank to do anyhthing anyway??? makes no sense. I took that strut off and

laid it in my MC parts drawer, looks nice in thare. but my point is........

do you think it is possibe to hit the sending unit while trying to remove the

tank?
cjc

cjc

I've been under there a few times to pull out SAS and canister crap, but the sensor is high on the side of the tank, so I don't think I would have bumped it. My leak looks like Kengray's photo in the gallery. I guess I'll ask the dealer about it since I am in warranty. Either way, I don't think I'd like to catch on fire. Thanks Joe.
cjc

cjc

I had my dealer check it out. He said the sensor was not attached tight and the O ring had allowed some fuel to leak which, apparently, dissolves the sealant around the sensor and it all runs down the inside of the tank. So, he tightened it up and resealed it. So far, so good. Need to keep an eye on it as it may need a new ring.

Now maybe my gas mileage will improve!