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Gas leak

1415 Views 5 Replies 4 Participants Last post by  Six5
I have a 2000 TL1000r. In great condition but after riding one night,I woke to fresh gas leaking the next morning. It was coming from gasket bolt area so I went to tighten them & it slowed the leak. I figured it needed to be tightened more so when doing so, a bolt broke off into the gasket plate. After extracting it I unintentionally made the home bigger where the bolt goes bc while extracting, my bit broke off in the screw and it was a mess 馃ゲ but I got it (bolt stem) out!
Ordered new bolts and they all fit but the one I had to extract..
U guys think the permeatex sealant will do the trick or will it need more than that?
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I have a 2000 TL1000r. In great condition but after riding one night,I woke to fresh gas leaking the next morning. It was coming from gasket bolt area so I went to tighten them & it slowed the leak. I figured it needed to be tightened more so when doing so, a bolt broke off into the gasket plate. After extracting it I unintentionally made the hole bigger where the bolt goes bc while extracting, my bit broke off in the screw and it was a mess 馃ゲ but I got it (bolt stem) out!
Ordered new bolts and they all fit but the one I had to extract..
U guys think the permeatex sealant will do the trick or will it need more than that?
Take a browse of this if you haven't already.


If you can find a suitable over-size bolt to fit the chewed up hole you should be ok.
Another option for the infamous TL fuel leak is the popular fix on Facebook.....

For the TLR only:
It involves the Viton o-ring in the link below. It fits around the base of the shroud surrounding the fuel pump.
Once bolted together, it rests between the flat surface of the pump plate and the very edge of the tank opening flange.

345 Viton O-Ring, 75A Durometer, Round, Black, 4" ID, 4-3/8" OD, 3/16" Width (Pack of 2): O Ring Seals: Amazon.com: Industrial & Scientific

I have not used it personally, but it has many good reviews on FB.
"It involves the Viton o-ring in the link below. It fits around the base of the shroud surrounding the fuel pump.
Once bolted together, it rests between the flat surface of the pump plate and the very edge of the tank opening flange. "

So the OEM gasket sealing plate is not used?
So the OEM gasket sealing plate is not used?
I have yet to personally install this O-Ring fix.
However, according to posts I have seen on FB since my last post in this thread, the OEM gasket plate is used in conjunction with the o-ring, but ONLY the metal plate is used. The OEM neoprene seal is removed from the metal plate. The plate remains to provide proper spacing for the o-ring compression when the pump plate screws are torqued (very lightly) down.

See the manual for torque specs - page 4-51.

You can also lightly grease the o-ring to prevent it from binding/twisting during installation.
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