Check Valve issues...
Tourer
Joined: Mar 2014
Posts: 271
Likes: 66
From: Canada
Well, I replaced the O-rings. Many thanks to Mike at Fuel-Tool for helping me out.
Much to my surprise, the O-ring in the fuel line was a total ***** to get out. It had managed to weld itself to the metal connector and we had to pick at it for quite a while. A lot of it came out in tiny pieces. Eventually there were two sections of ring left that we were able to grab that came out whole.
Mucho kudos to my wife who has excellent close vision who did most of the work getting the O-ring in the check valve out - my reading glasses just didn't work at that distance. We had the bike over on its side but it still involved working upside down.
I rode the bike for about 5 minutes and there was no fuel leak but I was lying awake last night wondering if any pieces of o-ring got into the fuel line. I inspected it as well as I could and didn't see anything. I'll take it out today and we'll find out. I don't want to learn how to replace injectors!
Much to my surprise, the O-ring in the fuel line was a total ***** to get out. It had managed to weld itself to the metal connector and we had to pick at it for quite a while. A lot of it came out in tiny pieces. Eventually there were two sections of ring left that we were able to grab that came out whole.
Mucho kudos to my wife who has excellent close vision who did most of the work getting the O-ring in the check valve out - my reading glasses just didn't work at that distance. We had the bike over on its side but it still involved working upside down.
I rode the bike for about 5 minutes and there was no fuel leak but I was lying awake last night wondering if any pieces of o-ring got into the fuel line. I inspected it as well as I could and didn't see anything. I'll take it out today and we'll find out. I don't want to learn how to replace injectors!
Outstanding HDF Member
Joined: Dec 2012
Posts: 2,557
Likes: 235
From: Texas
I experienced the exact same problem when I replaced the tank on a 2004 LR last year. I unsuccessfully tried to replace the o ring a couple of times before I realized that I was wasting time and pissing in the wind, so I just replaced the entire line with a new stainless braided line HD p/n 63020-04...problem solved.
...as for buying the tool, I am all about getting the right tool for the job but that tool is $100, and a replacement stainless steel braided fuel line from MoCo is $39.95...this is a no brainer for me when I can almost purchase three premium braided stainless steel fuel lines from the dealer for the cost of a tool I may use only once...and get the job done and back on the road quicker to boot.
...as for buying the tool, I am all about getting the right tool for the job but that tool is $100, and a replacement stainless steel braided fuel line from MoCo is $39.95...this is a no brainer for me when I can almost purchase three premium braided stainless steel fuel lines from the dealer for the cost of a tool I may use only once...and get the job done and back on the road quicker to boot.
Tourer
Joined: Mar 2014
Posts: 271
Likes: 66
From: Canada
Good news - ran the bike for half an hour and there were no problems. I'm sure if there was any crud in the line it would have fouled the injector by then.
Thing about the tool is that we were pretty sure it was the O-ring inside the check valve that was the problem. Replacing the check valve requires and working inside the tank and another special tool to remove the inner fuel line.
Both the O-ring in the fuel line and check valve came out "square". Yes it was still a ring but the O was squared off. Who knows which one was leaking? But they both needed replacing.
Thing about the tool is that we were pretty sure it was the O-ring inside the check valve that was the problem. Replacing the check valve requires and working inside the tank and another special tool to remove the inner fuel line.
Both the O-ring in the fuel line and check valve came out "square". Yes it was still a ring but the O was squared off. Who knows which one was leaking? But they both needed replacing.
Thread Starter
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6th Gear
Joined: Aug 2015
Posts: 11
Likes: 0
From: Utah
finally finished mine
Well, the snow started melting here so I finally got around to fixing mine. I was able to pull both o-rings out without purchasing the tool. I just used a a couple toothpicks. I tried following joebedford's advice and laid my bike on its side, but I still couldn't see up the check valve well enough, so I wound up unscrewing the valve from the tank just so I could see straight down into it. That made things so much dang easier.
RIPSAW was right, I had blown the upper o-ring out of its groove. All I had to do was push it back down and make sure the new lower o-ring was in it's groove and put everything back together. It was still leaking very slowly, so I sprayed some carb cleaner in the check valve to clean out any debris and that seems to have done the trick. I've run it for just under an hour and it's sat for a few days now without a leak yet.
Anyways, thanks for everyone's help. Here is the finished product - new bars and a tank lift. I'm happy with the results!
RIPSAW was right, I had blown the upper o-ring out of its groove. All I had to do was push it back down and make sure the new lower o-ring was in it's groove and put everything back together. It was still leaking very slowly, so I sprayed some carb cleaner in the check valve to clean out any debris and that seems to have done the trick. I've run it for just under an hour and it's sat for a few days now without a leak yet.
Anyways, thanks for everyone's help. Here is the finished product - new bars and a tank lift. I'm happy with the results!
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OneBlackFly
Ignition/Tuner/ECM/Fuel Injection
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Apr 23, 2008 09:40 AM
