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OK, I found and fixed the leak but I have a confession. When I was installing the fuel pump assembly in the tank one of the mounting screws was sticking some and I over torqued it and it sheared off in the tank plate. Didn’t think I was wrenching too hard but, I was. So I drilled out the screw and retapped it. No big deal? Turns out the screw holes don’t go all the way through the plate, but my new “fix” did. There was enough of a gap in the threads to allow some fuel to seep out. I couldn’t figure out where the leak was originally because the seeping fuel took several minutes to appear and seemed to come out from different places.
I got a small rubber (fuel resistant) washer to put between the plates in the offending screw hole and after two weeks and also running the bike, there’s no leak. Here’s a pic of my project so far, all that’s left is putting together the electrical connector and getting a seat.
I’m going to sit down later and post up my project (and lessons learned). Maybe it will help someone else out.
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