2008 TE610 leaking fuel on ground with full tank

[dannyw68]

Hi everyone,

I just picked up a 2008 TE610 and am loving it. The only issue I have is that when I fill up the tank and park it in my garage, it always leaks a small amount of fuel on the ground. Its a slow leak, maybe one drip every 2-3 seconds. I'm guessing the previous owner removed some of the emissions stuff, but I'm not familiar enough with the bike to know if this is the case.

Is this a common issue on these bikes? Any help you can offer would be greatly appreciated.

Thanks,
Dan

 

[Muddy Waters]

Do you know where is it leaking from ?
The tank itself ?
A hose that connect from the bottom of the tank to the engine or maybe the former emission junk that connect to the top of the tank ?

 

[K7MDL]

There is a good chance the top left tank vent hose is not routed high enough above the tank to account for fuel exansion as it warms up on a full tank if the PO removed the original canister and check valves and rerouted hosing. Mine would gush on the ground at fill up when I first got it (used) until I realized the open hose was routed straight down to the skid plate.

 

[dannyw68]

Hmm, that makes sense. I'll check this out tonight to see if it is the problem.

 

[Stroker Ace]

I routed my tank vent hose straight forward, under the fork crown, then back over the handlebar clamps, then into the steerer tube. Problem solved. And NO the over splash of gas once in a while will NOT wash the grease out of the head bearings..... Good Luck....

 

[K7MDL]

I routed my tank vent hose straight forward, under the fork crown, then back over the handlebar clamps, then into the steerer tube. Problem solved. And NO the over splash of gas once in a while will NOT wash the grease out of the head bearings..... Good Luck....

It just runs down your fender and drips onto the hot header pipes and flashes into a fire! I have not personally heard of that happening though. Just seems like it could happen.

 

[dannyw68]

Turns out the leak was from that hose. It was routed straight down from the tank. i rerouted it and now there is no leak on the ground.

However, I did notice that when the bike is leaned on the kick stand, some small amount of fuel leaks from around the fuel cap. I opened it and the level is below the rim, yet somehow it is getting siphoned up and out of the cap? Its not much, just three or four drizzles, but really strange. Any ideas?

 

[Stroker Ace]

It just runs down your fender and drips onto the hot header pipes and flashes into a fire! I have not personally heard of that happening though. Just seems like it could happen.

You need a spark to ignite the fuel. I should have been blown up 30yrs. ago..... Next time you go to a shop, look and see how the new dirt bikes do it. That's where I got the idea. The idea of doing it that way gets a loop of hose quite a bit higher than the level of the fuel, you'll get a minimal amount drips with a full tank from hitting some rough stuff, but after a few miles.... nothing......


Happy Trails...

 

[Stroker Ace]

Turns out the leak was from that hose. It was routed straight down from the tank. i rerouted it and now there is no leak on the ground.

However, I did notice that when the bike is leaned on the kick stand, some small amount of fuel leaks from around the fuel cap. I opened it and the level is below the rim, yet somehow it is getting siphoned up and out of the cap? Its not much, just three or four drizzles, but really strange. Any ideas?

Ok... now you have the same other problem I had. The O-ring on the base plate for the cap is leaking YOU NEED TO FIX THIS BECAUSE WATER WILL GET INTO THE FUEL. Guess how I know this****************************************! I took the three allens out, removed the plate and could see the tank wasn't completely flat and could see where the O-ring wasn't sealing. I got some neoprene gasoline proof gasket material, cut to fit, applied high priced gasoline proof gasket sealant to the new gasket, left the O-ring in place, bolted it back down snug and evenly, problem solved!!! Fix this asap or you can water up the fuel and not know why..


Don't forget to check out the Adventures of Lonerider in the ride section

 

[Stroker Ace]

It just runs down your fender and drips onto the hot header pipes and flashes into a fire! I have not personally heard of that happening though. Just seems like it could happen.

Note vent hose on brand new show room Huskys, I doubt the factory or the dealers would do that if they thought they would catch fire.....

 

[LRPct]

Turns out the leak was from that hose. It was routed straight down from the tank. i rerouted it and now there is no leak on the ground.

However, I did notice that when the bike is leaned on the kick stand, some small amount of fuel leaks from around the fuel cap. I opened it and the level is below the rim, yet somehow it is getting siphoned up and out of the cap? Its not much, just three or four drizzles, but really strange. Any ideas?

According to the manual, you're supposed to keep the level below the LOWEST part of the cap when installed, nevermind the rim...I regularly fil mine up well above that though, but only when I'm riding on the street for a few miles and I know I'm just gonna burn the gas away well before I park it.