I saw a diagram of TE630 gasket / tank / fuel pump - it shows the gasket between metal cover plate and top of fuel pump, then fuel pump drops in and lip sits on top of the tank flat surface. Is the diagram incorrect? How do you have it on your TE630 bike? Seems like if you follow the diagram, the gasket is only pressing against the pump. How does the fuel pump seal against the tank surface? I've had my TE630 2 years, sealed it 2 times with Permatex Fuel sealant on the gasket, but I put the gasket between the fuel pump and the tank surface. First time fuel leaked because I had one way valve causing excessive tank pressure. Took that off. Then water pump leaking coolant into oil.. finally got that fixed. Now back to tank - it was a hot day and glazing fuel the color of the blue sealant. Still, want to know the logic of the gasket placement in diagram. Thanks!
Blue Sealant? It appears sealant isn't gas compatible and should be removed. Haven't had my fuel pump out but checked service manual and no indication of where o ring should be positioned. The diagram is confusing as one would think the o ring should be between tank and pump for proper seal as you said Flange-pump-o ring- tank.
It's the Permatex Permashield, fuel safe. Thank you for the feedback. I almost tried the diagram way, but didn't want to do all the work and have it bleed gas in my garage.
Have not seen the assembly apart so cannot comment with any certainty but if you are having leaks due to sealing problems a larger o ring may help as long as it is nitrile or other gas resistant type.
Willie is correct on order: flange to pump body to oring to tank. Popular leak area- mine leaked. The tank deforms there- I used a new one. Slightly larger may help too, but I used stock oring w/ fuel safe sealant. Both of my stock tanks are pretty warped there and the one on now has been there a loooong time w/out issue ( just used a very generous bead of the sealant.)
I had a similar issue on different tank: I had a Safari tank on my 610 and my fuel pump leaked. I tried multiple sealants and o-ring combinations. None of the fuel-safe sealants I found permanently fixed my issue . I eventually took the tank to a plastic welder and he built up the surface of the tank around where the fuel pump mounted, and then machine-sanded the area flat. This fixes the issue.
