Fuel pump seal leaking.

[PaulC]

Mine got repaired under warranty. The entire tank had to be replaced, My friend owns the dealer who did the work and he said it was a Nightmare of a job to do. I sold the bike before it even left the dealership. Had the new owner pick it up there. I didn't even want to see it again.

Well thats a bummer
I kinda like my TR and when you see what the others are offering (KLR, DR, XT and the KTM) the TRs a bargain with FI.
5 years & 67k klm's it has Never let me down.

 

[jetsun]

I love the bike the fuel leak around the pump is really getting to me I dread fueling it up

I need to determine : does it matter if the bike is cold or hot? then it would be the pressure if only hot engine causes the gas expansion but I gutted the vent cap
never had issues with tank overflowing after a ride in +90 temps
need to work more on it I guess
I didn't use specific torque value lightning it just a decent hand feel
I don't think the metal ring can have anything to do with it It just holds the pump in place...?!
will post some pictures of the tank after I take the pump out again

thank you

 

[jetsun]

Hi there it has been a while Finally I have found the problem, one of the brass screw holes for the ring is not tight , may have a crack and it seeps the gas
any idea to fix it seal it glue it reset the brass insert here is the picture

 

[glitch_oz]

https://goo.gl/v83R37

https://goo.gl/Drwpm4

 

[jetsun]

https://goo.gl/v83R37

https://goo.gl/Drwpm4

thanks a lot, will try it definitely ! love the bike and this gas leak drives me nuts
the links you sent had a note that it can not be shipped to USA but I googled it and its available no problem .
thanks

 

[Antti Mikkonen]

thanks a lot, will try it definitely ! love the bike and this gas leak drives me nuts
the links you sent had a note that it can not be shipped to USA but I googled it and its available no problem .
thanks

Hi jetsun just wondering how you went with fixing your leak issue? I have a feeling the brass screw holes might be causing my leak as well.

 

[jetsun]

Hi jetsun just wondering how you went with fixing your leak issue? I have a feeling the brass screw holes might be causing my leak as well.

Hi Antti

Didn't fix it yet
I have ordered the Versachem tank repair kit suggested by glitch_oz , I'm attaching screenshot from amazon.
I'm kind off desperate at this moment, Im intending to try to pull the brass sets out of the tank and reset it with the epoxy kit, found out that other are loose too
you can put the screw a bit in and try to wiggle you will see...
if this doesn't work then I'm going to replace the tank I guess
Interesting enough Bike bandit is listing two tanks?! see the pict attached, two different part numbers , price is double on one of them...
I called the rep and he told me both are available to ship , one is taged :for American market?! couldn't tell me more info nor technical difference if any

any body knows whats up

The leak became a problem after I lowsided a couple of times during a BMW rally, trying to impress people with my sliding skills or rather lack of it.

I think the design of the fuel pump, free floating in a way inside of the tank, allows for this
when you fall the weight of the pump exerts prassure on the ring and stresses the brass screw sets ?! that is what I suspect...may be wrong

here I'm thanks for your interest
also anybody who replaced the tank on Terra and has some pointers please share

J

 

[glitch_oz]

if this doesn't work then I'm going to replace the tank I guess
Interesting enough Bike bandit is listing two tanks?! see the pict attached, two different part numbers , price is double on one of them...
I called the rep and he told me both are available to ship , one is taged :for American market?! couldn't tell me more info nor technical difference if any

any body knows whats up
.

I'm pretty sure there is only ONE!!! tank for ALL models!!! Strada/ Terra/ ANY location on the globe...
I'd buy the cheaper one....

I think the design of the fuel pump, free floating in a way inside of the tank, allows for this
when you fall the weight of the pump exerts prassure on the ring and stresses the brass screw sets ?! that is what I suspect...may be wrong
here I'm thanks for your interest

Wouldn't be a surprise... the TR-"engineers" seem to have been on some heavy-duty vino when tasked with the job.
I think it would be wise to remove, clean, dry etc any loose and easily removable inserts for repair first.... before trying to extract + fix the rest.
From my long-time background of working with all sorts of plastics (part of my job)...this should work ok if done "by-the-book" (read instructions carefully).

There's also the option of looking out for bigger/ differently shaped inserts for further/ later repairs, should the first repair eventually fail.
The bolts are only standard M5's, I think...M6?...can't remember, only took the pump out once (to have a look)

 

[jetsun]

I'm pretty sure there is only ONE!!! tank for ALL models!!! Strada/ Terra/ ANY location on the globe...
I'd buy the cheaper one....

I also think that there is only one tank

I saw though somewhere in this forum that the non USA Terras and Stradas come without the red "funnel" in the gas tank...

 

[glitch_oz]

I saw though somewhere in this forum that the non USA Terras and Stradas come without the red "funnel" in the gas tank...

...gotta check (got one of those), but I thought that was just an extra/ separate part.

 

[jetsun]

Big price difference, would it be the canister?
Never got a red funnel, haven't missed it
View attachment 91895
View attachment 91896

yeah...same part numbers as in Bike Bandit post, same price difference

I find it interesting and why the hell would the tank cost double in USA....man?!

the red funnel is really pain in the arsch because it allows you to get fuel only from the left side so you can properly feed the nozzle into it...
well what the hell
I'm riding my terra like a hooligan carefully putting only some 2 gallons of fuel each time to avoid the leak
first cold days Im draining the tank and doing repair
will take some picts and post
if that fails it looks like replacing the tank will be my winter project

 

[jetsun]

Here it is guys...It looks like I have managed to fix my biggest headache with Terra
persistent gas leak around the fuel pump

 

[jetsun]

I'm sharing with all of you what have been done

It took a lot of testing to determine where exactly it is leaking
initially I thought that the gasket is bad....NO!

or the fuel hose union is bad....NO!

and then the breather hose is pinched...NO!

so then I started digging with a scalpel around the brass sets screw holes for the ring
I blocked off the gas tank opening by wrapping some plastic around the gasket and putting it like that

 

[jetsun]

then I cut all around the brass sets with a scalpel and discovered that 3 of them have a void on the side of the opening and you can actually see the cream lining of the tank
I made the cutting deep enough to be able to insert tip of of a thin syringe

 

[jetsun]

after a long research I chose to fill the gaps and the voids with JB Weld Plastic bonder
the tank is made with some polyethylene based thermoplastic and JB Plastic bonder claimed to stick to polyethylene

 

[jetsun]

here are some pictures of filling before sanding
it sets in 30 minutes but I waited 24 hrs

 

[jetsun]

then all I did is sanding with 120 grid and 220 final to make it extra smooth
cleaned the residue with some alcohol and reinstalled the fuel pump

initial impression after sanding very positive it looks like the compound blended tight with the tank

I made a temporary cover for the opening by tracing the gasket on 1" thick foam insulation
and inserting it in the tank as you can see
no dust got in the tank

 

[jetsun]

with great excitement I reassembled the fuel pump and started the bike with a little bit of gas in it

rode it some 20 miles and went to the gas station filled it up to the top****************************************!


no leaking ....man I missed the bike man I'm happy


this is it

I noticed that now bike doesn't smell like gas like before it used to

thanks for reading

Jetsun

 

[jetsun]

Hi jetsun just wondering how you went with fixing your leak issue? I have a feeling the brass screw holes might be causing my leak as well.

please checkout my recent posting regarding the gas leak

 

[fastkx125]

Yayyyy finally fixed! Fingers crossed. It was a great bike.