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I am almost done with putting my bike back together and when installing my new fuel line into the quick connect it pinched the o ring up there damaging it causing a huge fuel leak. I ended up pulling it out and shoving a green ac o ring in its place and got it to stop leaking for now. I will probably have to swap it out later for a viton o ring but it is not that big of a deal. The way I got it out was a hooked pick and a mirror. It was simple except every time you touched the post in the middle fuel would flow out. It was like playing the game operation.
Just some information about the o ring. It is the same size as the oil drain plug O ring and you can buy viton Oil drain plug o rings off amazon and eBay. I ordered a set and will be swapping it out once they show up
Good thing you were able to pick it out... I wasn't so lucky. Spent 3 hours upside down or with a mirror trying to pick the damn thing out only to destroy it to the point it was stuck.
Finally, spent the $110 or whatever on the quick disconnect/ inner tank line and replaced the thing.
Wondering if you relieved the fuel pressure before pulling the quick disconnect? I didn't the first time I pulled the tank and had this problem. The next time I pulled the tank, I pulled the fuel pump fuse and tried to crank her over a few times... no issues with the quick disconnect o-ring.
The green o rings do not hold up long it swelled up to almost twice the size and started to drip a little bit no big deal. I have a set of viton o rings from harbor freight and I was able to use an o ring sized A110 9.19 x 2.62. It is slightly thicker than the stock one which means you really have to lube up the quick connect. I used wd40 to lube it. I tested 2 o rings to make sure I did not pinch anything when installing it cause it is a tight fit. Upon inspection the o ring worked out great and no more leak.
These are the tools I used to fix it. I bought a cheap pick set from harbor freight and it comes with a 90 degree pick which I used to pick out the old one. You just take the pointy end and pop it in the o ring then pull it out. The other one is the straight pick that Bent in a 90 degree and grinded it smooth so it won't damage the new o ring while pushing it in place. The mirror is my wife's and she is mad I ruined it but it is needed to see in the hole.
The o ring at the top is there to stop fuel from flowing out when the disconnect is pulled. I didn't have the right size o ring for that so I reused the old one. the fuel line does not hold a lot of gas so if it does not stop the fuel from leaking only a little gas comes out. once the quick connect is hooked up that o ring will not cause an external leak. There is a small o ring on the fuel line connection and that also does nothing to stop fuel from leaking. The only o ring that does anything is the forward o ring that I replaced. I read a few post where people replaced the fuel line from the fuel injectors but that won't stop any leaks. It is much easier and cheaper to replace the o ring that replace the quick connect. It takes about 5 min to replace the o ring
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Pinched fuel quick release o ring.
