How to stop my S4 from leaking gas...

[Dustin1231]

I walked out to the dumb of a grage i keep my baby in. Looked down and noticed a small yellow puddle. Followed the yellow stain up the side of my frame to the bottom of tank.  Noticed that it looked like the gas was coming out of the "low Fuel" light sensor. So i got a wrench and started to tighten it. Well i thought i had the problem solved, but was riding the bike and noticed that it had leaked down my pant leg... I cant tell for sure if its leaking at that spot.. But it does look like it. I remember reading on the old site about people haveing leaking tanks. But didnt see anything on here. Anyone ever have this happen before.
Thanks [moto]

[ducpainter]

I walked out to the dumb of a grage i keep my baby in. Looked down and noticed a small yellow puddle. Followed the yellow stain up the side of my frame to the bottom of tank.  Noticed that it looked like the gas was coming out of the "low Fuel" light sensor. So i got a wrench and started to tighten it. Well i thought i had the problem solved, but was riding the bike and noticed that it had leaked down my pant leg... I cant tell for sure if its leaking at that spot.. But it does look like it. I remember reading on the old site about people haveing leaking tanks. But didnt see anything on here. Anyone ever have this happen before.
Thanks [moto]

My experience has been they leak from the hinge not the sender.

The repair require brazing the hinge plate and coating the tank with a sealer. I use POR-15 and haven't had one fail yet.

[johnster]

My experience has been they leak from the hinge not the sender.

The repair require brazing the hinge plate and coating the tank with a sealer. I use POR-15 and haven't had one fail yet.

+1 ..... The exact same thing happened to my S4 last year and it's a common problem. Turns out that it is usually caused by lifting the tank up too far when accessing the battery/airbox/etc.. The hinge is only spot welded IIRC & cannot take much strain, so be careful. I had mine internally coated using POR-15 and it's been fine ever since. Do NOT try and band-aid it (JB Weld or Bondo both come to mind), as you're just masking the true problem...

[Rameses]

This made mine stop leaking gas.   


http://ducatimonsterforum.org/index.php?topic=5204.0

[Speeddog]

Also, riding with the latch loose or unhooked doesn't help the hinge bracket either.

[NAKID]

Don't ask Rameses...

[Dustin1231]

once i get the POR-15. what do i need to do?

[Dustin1231]

do i put it on the inside of the tank??

[johnster]

do i put it on the inside of the tank??

Yes, and I don't know if I'd try to do it myself to be honest w/you. 

-You have to detach the entire filling hatch assembly and let the tank fumigate for at least 24 hours before you seal it (at least that is how my dealer did it). I don't think it's as easy of a process as just pouring the stuff in + swirling it around. You may want to get someone who's done it before take care of it.

[ducpainter]

If you don't reinforce the hinge it will leak again.

[scooby]

I fixed mine successfully  (after trying unsuccessfully to have it brazed by Speedymoto which is just down the street...) by putting a expoxy compound on the OUTSIDE of the tank. It is a 2 part epoxy that it like putty and hardens enough to sand, drill, whatever... I built up the hinge, did the seam at the edge, pretty much went berzerk on the over kill (knowing none would be visible due to the seat covering it...)

So, it worked. Has held for 6k miles (3 months) so far.

The product is from BBS coatings...

Oh yeah; this is my second leaky tank! First one was welded successfully (again by speedymoto).

This is the shit:



KBS NuMetal :: Epoxy Putty
KBS NuMetal Epoxy Putty is a easy-to-use, two part putty you simply mix and mold like clay â€" no complicated weighing or measuring required. Available in one pound box in BLACK, TAN, & WHITE!

NuMetal Epoxy Putty is an easy-to-use, two-part putty that mixes like clay but hardens like steel! NuMetal bonds, seals, fills, insulates, anchors, caulks and waterproofs. It cures without shrinking or sagging and can be drilled, tapped, sanded, primed and painted. NuMetal will not only stick to damp surfaces, but it will cure underwater!

Our Black NuMetal is ideal for automotive applications…if the surface coating sustains damage, the black epoxy putty beneath remains unseen! Use White NuMetal for marine applications and boat repairs. Satisfaction guaranteed!

www.kbs-coatings.com

[johnster]

^^

Yeah, my dealer told me that this is nothing more than a "band-aid", and you're just masking the problem, but hey.. If it works, than it works!!   

The main thing is to keep the gas IN the tank, so I suppose anything you use is fine as long as it holds.. Hell, I almost use JB Weld which probably would've been a bad idea..

[ducpainter]

...ask ducvet how well epoxies on the outside of the tank work.   

[scooby]

^^

Yeah, my dealer told me that this is nothing more than a "band-aid", and you're just masking the problem, but hey.. If it works, than it works!!   

I gave up a long time ago listening to my dealer... 

[johnster]

I gave up a long time ago listening to my dealer... 

I hear ya!!  I've gotten questionable advice from mine in the past.