Maintenance & Technical > KX500 Original

Gas Leak

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don46:

--- Quote from: Johnniespeed on April 25, 2010, 04:43:58 AM ---Runabout
  I consider myself a master at patching things that should not be fixed and I love a challenge.  Most normal sane people would throw that tank away and buy a used one, but not me.  What I would try is to make two gaskets that match the pattern of the fuel shut off valve, then I would cut a piece of sheet metal to the exact pattern of that gasket, I would weld two 6mm bolts in the sheet metal. ( if they use a 10mm wrench the threads are 6mm-1.0 thread pitch)  I would place the sheet metal and one gasket inside the tank after preparing the tank, then place one gasket and the fuel valve on the outside of the tank and using two 6mm nuts ( again a 10 mm wrench is needed)tighten and test for leaks.   You may have to modify the instructions to suit the situation, but I think you will understand the theory that I am using.
 I have patched much more complex things than this, but the double gasket on the plastic tank has always worked great every time I have used it.
  Hope this helps. John

--- End quote ---

So, ho do you get the sheetmetal/gasket in the tank? are you going to remove the nutserts and drill them out to fit your sheetmetal and gasket? What if the tank isn't flat where the sheet metal goes? While I'm all in favor of fixing anything and everything, I'm also a realist, and rather than have a good day of riding ruined because my tank was leaking, or worse yet get burned because of it, I would find another tank.

What I find interesting is the fact that the tank is leaking out od the threads, the nutserts are blind bottom and are formed in the tank so if it the bolt gets tight I would find it hard to believe that the tank is damaged, are you sure the valve doesn't have a crack allowing fuel to run down the bolt making it look like its leaking from the bolt.

runabout:
Don that is a good question
The tank has heat damage in the area of the petcock
When close CSI from inside the tank the heat was enough to distort the
plastic nipple that is formed to hold the insert...
I plugged all old holes and mounted the petcock in new location
approx 1/4 inch from old location and no leaks now
The interesting thing is that the outside of the tank has min heat distortion
but the inside that holds the insert looks bad (big/swollen) gum drop look to it and that is why it was leaking domw the bolt
Regards

blueoval:
Did you take any pictures of the tank so I could get a visual?

runabout:
I did not take any pics of the bike but I can...
do you still want to see even though it is fixed...?
My JB weld is not so purdy so of course everyone will want to see that  :-o
Regards

matzilla:
you could try some motoseal. it is for outing cases together. made to be in contact with gas and could seal it right up. do the whole base of the petcock. let it dry 24 hours before adding fuel.

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