gas leak

[fuzzzyman]

2001 RSV, 13,000 miles

Back in 2003 my priller had a gas leak, figured out it was a warped tank. They replaced the tank and things have been good. Get home last night and its leaking again, gas dripping out under the fuel pump...

Any suggestion on how I should approach my dealership...

Is the tank still under warranty?



thanks

fuzz

[kzmille]

It seems like it should be replaced regardless since this is such a serious safety issue. In the mean time check out this thread if you haven't seen it.

http://www.apriliaforum.com/forums/s...ad.php?t=59629

The part pertaining to your situation starts with post #6.

http://www.apriliaforum.com/forums/s...06&postcount=6

[ApriliaMille]

Last year my 2000 R had the same problem, and even being far out of warrenty Aprilia Ga, replaced my tank.

So even if your dealer doesn't want to, make them take the issue to Ga.

And if they still hesitate, point out the NTSC would probably frown on gas leaking on exhaust headers.

[fuzzzyman]

Thanks guys.

No real fight at the dealership, they called aprilia USA and it will be covered under warranty.

They are not giving me a new tank, going to start by replacing the gasket and see if that fixes it. Think it will be a temporary fix, then start leaking again. Kinda at there mercy, if I want it fixed for free I have to follow their rules.

Only thing I don't get: I'm tank #2, what are the odds that I get 2 warped tanks?

fuzz

[kzmille]

I don't know anything about odds but so far your batting a thousand. Hopefully if it is replaced again it will be the last time.

[RFM]

Thanks guys.

No real fight at the dealership, they called aprilia USA and it will be covered under warranty.

They are not giving me a new tank, going to start by replacing the gasket and see if that fixes it. Think it will be a temporary fix, then start leaking again. Kinda at there mercy, if I want it fixed for free I have to follow their rules.

Only thing I don't get: I'm tank #2, what are the odds that I get 2 warped tanks?

fuzz

Hey Jay,

I had the same issue. I ended up using an oversized o-ring. A new ring will not do anything. If they try and tighten the bolts it will just warp the composite more. I have extra oversized o-rings if you need. It is a thirty minute job that I can help out with if you want. I will guarantee that your old o-ring is not the issue, and that replacing it with a new version of it will do nothing.

E-mail me at rfm@rfmillington.com, or drop a pm. And you can always catch up with us at the friday night Bike Night at Iron Pony.

rfm

[RFM]

Oh, and the tank can be warped due to overtightening the fuel pump bolts- something the mechanic that changed the tanks for you might have inadvertantly done.

[fuzzzyman]

had the same issue. I ended up using an oversized o-ring. A new ring will not do anything. If they try and tighten the bolts it will just warp the composite more. I have extra oversized o-rings if you need. It is a thirty minute job that I can help out with if you want. I will guarantee that your old o-ring is not the issue, and that replacing it with a new version of it will do nothing.

Thanks, You have mail


fuzz

[mthiese]

My tank is warped. I had the shop take off the tank and re-seal the pump with the original o-ring. It worked for a second and then it was leaking even worse than when I took it in. They charged me 2 hours of labor for that. $133. I bought the oversized O-ring you suggested and took the bike back in. The did the same process over with the new O-ring, and guess what. NO LEAKS! I'm stoked. I have extra oversized O-rings if anyone needs one. Just let me know. I also have an extra starter that's perfect, and a brand new starter relay for a 2002 RSVR 1000 Mille. After replacing the starter and the relay (the easy fixes), it turned out to be the Sprag clutch. Not easy, and $$$!

matt_thiese@yahoo.com

[Fustern]

Maybe its not the warping of the composite tank but rotting of the fuel vent tubes inside the tank. This seems to be a common thing. If not rotting, perhaps they slipped off the connector points just under the gas cap opening?


Make sure your vent tubes are connected to the nipples on the bottom of the fuel pump plate so that if that is the problem then at least it will drip onto thr ground and not dump so directly on the headers (BOOM!).

Either way let us know what happens.