Ducati Monster Forum

So I found I had the infamous fuel tank hinge leak. Tore tank apart, did the por 15 sealer and am now in the process of putting it all back together.  I can't for the life of me get the ring for the gas cap to go back in.  Is there a trick to getting the rubber seal to squish enough to get the screws in?

I hope you did more than just use POR in the tank to fix a hinge leak.

You need to grease the o-ring.

and be careful not to get your big Popeye forearms stuck in the tank.......Don't ask..... :-[

Not trying to treadjack, but I'm dealing with a hinge leak right now too. Nate or Herm, do all carb tanks have that little "drain plug" beside the hinge plate?

The drain plugs disappeared sometime in the late run of carbie bikes.

Thanks, I had a local bike builder who had experience with those leaks lined up to do the job til he saw that drain plug.  He'd never seen one and truthfully I hadn't noticed it either.

My experience as well.

>> I hope you did more than just use POR in the tank to fix a hinge leak.

Several years ago I fixed my hinge leak with a epoxy tank sealer (not POR but similar). Has lasted well BUT I feel the trick is to NOT use the little prop to hold the tank up when lifted. I use a piece of wood about 18 inches long which goes between the tank and the tab for the tank holding down thingy. Holding up the tank with the prop puts too much strain on the hinge IMO, stupid bit of design.

Mine is FI not carb BTW but 'spose same arrangement.

Plastic fuel sender nut with a hairline crack can be mistaken for hinge leak.

BTW: I have two EFI Monsters in my garage with hinge leak.   :-\  How did I get so lucky?

So I still can't for the life of me get this damn fuel door assembly on. I've greased everything. There a green o ring and there's a black rubber seal between the tank and the assembly. It's almost like the black seal won't compress enough to allow the fuel door down far enough for the set screws to grab. The screws just push it up and out. Is it just a royal p.i.a. or am I just making it harder than it needs to be?

The grease goes on the green o-ring. Clean the black rubber seal.

You need to fit the black rubber piece to the edge of the bung, and then push the whole assembly into the tank. Once in place the pressure exerted upwards on the black rubber from the edge of the tank will hold it fast, and then tighten the grub screws. If you tighten one opposite another it will hold everything in place.

It's kind of tricky, but not rocket science.

It's one of those things that once you figure out the first time, you can do again and again and again with NP. Like DP said it's a matter of getting one grub screw to partially thread then working around the piece firmly but with "finesse.

Got it!  The black seal goes around the outside, not in between. Went right in.  Thanks for all the replies. Should have it back together just in time for it to snow.  >:(