Major gas leak
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Joined: Aug 2009
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From: Conway, AR
Major gas leak
Decided to ride the bike back to work from lunch. Backed her out of the garage and started her up. Was buckling on the helmet when I looked down and saw gas POURING from the fitting that comes from the underside of the tank. Turned it off and the hose has a banjo fitting and it was real loose but couldn't figure out how to tighten it. Was in a hurry to get back to work so pushed her back in the garage and will look at the SVC manual when I get home tonight, just thought I'd plug the brilliant minds on this board before tearing into the manual. All I have to do is turned the ignition on and even without starting her she starts pouring the gas.
She's a 2000 Road King Classic.
She's a 2000 Road King Classic.
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Joined: Aug 2009
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From: Conway, AR
More to the story. Friend showed me that it was a quick disconnect going from the hose to the tank. Disconnected cleaned the hose end and re-connected and it's worse. Is it the hose that's bad or the quick disconnect fiiting?
Stellar HDF Member
Joined: Mar 2007
Posts: 2,034
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From: Michigan
Its the fitting . If its the newer style that you slide the outside up on the chrome part and insert the lower black part ? There is an O-ring that seals the outside of the fitting to the lower black fitting when its plugged in . That o-ring is either gone bad (most likely) or has a cut or a chunk out of it.. PM me your email.. I have a sketch and part numbers for the o-rings. I designed built and programmed one of the assembly machines for that part and worked where the part was made.. There was a real early version that was made by someone else but it wasnt a true quick disconnect and the later version is. Also on some of the early systems they had 2 fittings not like the 1 on the later models .
Road Master
Joined: Jul 2007
Posts: 863
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From: Dover, DE
Have you had the tank off recently? the hose they use for FI is a little more brittle than old neoprene. I was warned that heat from the motor combined with pulling or twisting some causes the line to crack and that may be what you're seeing...just an idea.
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From: Conway, AR
Dave, Thanks. I sent you a PM. Can this fitting be repaired? I have tons of commercial grade o-rings of different sizes. Anyhow if not and I have to remove the fitting will the gas run out of the tank? I will snap a picture at lunch if needed.
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From: Conway, AR
Thanks for the reply j but no I have not had the tank off. Really a strange deal to be riding one day with no mishaps and then park it and a day later it's got a bad leak. It's really not a leak it's more like a blow out. As soon as the fuel pump kicks in, it's gas all over the place.
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Joined: Aug 2009
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From: Conway, AR
Its the fitting . If its the newer style that you slide the outside up on the chrome part and insert the lower black part ? There is an O-ring that seals the outside of the fitting to the lower black fitting when its plugged in . That o-ring is either gone bad (most likely) or has a cut or a chunk out of it.. PM me your email.. I have a sketch and part numbers for the o-rings. I designed built and programmed one of the assembly machines for that part and worked where the part was made.. There was a real early version that was made by someone else but it wasnt a true quick disconnect and the later version is. Also on some of the early systems they had 2 fittings not like the 1 on the later models .
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Joined: Aug 2009
Posts: 70
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From: Conway, AR
The latest. If not for N8DC I would still be wondering. Anyhow I had to fix both the main fuel line and the return line by installing a new o-ring. N8DC (dave) supplied me with great info and pics. I will at a later date post these pics with deminsions and give Dave all the kudo's with hopes it will help the next guy/gal that has a major fuel leak.
Thanks Dave
Thanks Dave
Road Master
Joined: Nov 2007
Posts: 771
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From: St. Bonifacius, MN
Whiteduramax,
I look forward to your post with the o-ring info as I have had to replace the o-ring in my fitting and ended up purchasing a new fitting in order to get the o-ring since HD does not sale only the o-ring.
I look forward to your post with the o-ring info as I have had to replace the o-ring in my fitting and ended up purchasing a new fitting in order to get the o-ring since HD does not sale only the o-ring.