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Fuel leaking from overflow

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Fuel leaking from overflow Empty Fuel leaking from overflow

Post  Androo120 Fri 18 Feb 2011, 2:15 am

Im having probs with fuel leaking out the overflow on my 05-1200. It only happens when I fill up. Even only 3/4 tank. Seems to go after I get below 1/2 tank. Im going to have a look this weekend, but any ideas would help. It continues even while the bike is running, sitting at traffic lights, and continues while bike is off, after 12 hours or more, a puddle on the floor and still dripping. Im baffled.
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Post  gus Fri 18 Feb 2011, 8:59 am

I was thinking carbies but that half tank thing is making me think split overflow tube. i reckon its one or the other but i'm no mechanic.
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Post  Re-Cycled Fri 18 Feb 2011, 11:29 am

If it's the fuel tank overflow, on r/h side rear of tank, I'm thinking, a hole in the inner tank.
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Post  gus Fri 18 Feb 2011, 12:13 pm

I could be wrong but i think the overflow pipe starts at the filler cap, travels through the tank and exits bottom R\H side like R\c says.
If that tube has worn through or heat is expanding the fuel and trying to find a way out .
My girlfriends bike has a black tank and always dumps fuel after filling up and parked in the sun.
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Post  b12mick Fri 18 Feb 2011, 1:48 pm

On a hot day with a full tank I can understand, a lot of bikes will do that. But yours will do it on a 3/4 tank. As someone else suggested it could be a leak high in the tank.
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Post  Androo120 Mon 21 Feb 2011, 3:25 pm

I think you are all on the right track. Had a quick look on the weekend. Unfortunately it had a full tank and I was low on time. The right hand side of the tank has 2 tubes coming from it. 1 is thicker in diameter than the other. It is the larger one that has the leak. I will have another crack next weekend, if time permits, so I can drain the tank and remove what looks like a flange underneath for better access. I wonder if the overflow tube at the filler has come off and the top of the tube is just floating in the tank????? Thanks for the ideas.
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Post  Androo120 Wed 09 Mar 2011, 5:00 pm

I removed the tank. Found the larger of the 2 overfows has some sort of leak. Unfortunately, the tubes are copper and are welded as part of the tank. Looks like I am up for a new tank. Will put up with it for a while. Cant afford a new tank at the moment.
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Post  gus Wed 09 Mar 2011, 5:13 pm

Copper solders real easy .I used to be a leadlighter and used a soldering iron all day .I would be surprised if i couldnt fix that with out blowing
myself up .
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Post  Androo120 Sat 26 Mar 2011, 3:00 pm

I can solder also. Problem is, you cant get access. Its inside the tank. Would need to somehow split the tank.
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Post  gus Sat 26 Mar 2011, 3:32 pm

Carn't you get to it from underneath the tank.There is a fuel filter in there so it must come out .
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