leaky gas tank...

955 Views 9 Replies 6 Participants Last post by cyclecamper, Nov 4, 2013

cyclecamper

Discussion Starter · Nov 3, 2013

My tank never had any leak symptoms. but now I've been working on it a lot, lifting the front, clamping hoses back on, lifting the rear to work on the suspension with the hoses still attached and stretching to their max...

Now this TLS tank has a thick foam seal from the underside of the tank to I guess the airbox. My old '97 TLS didn't have this, but I assume it's stock on this 2000. Anyway, it's soaked with fuel! So I ordered a new seal for where the pump plate mounts. Meanwhile, I'd really like to better observe any leaks. Is this undertank foam rubber necessary? Is it replaceable? I can't find a part number for it. I assume it keeps rising heat from heating the bottom of the tank, which is a good idea. Is it likely I pulled the hoses enough to deform the plate or bezel or seal or something? I'm sure the pump plate has never been opened before. Maybe I can find better hose clamps somewhere too?

I'll drain the tank, make sure the mounting surface is flat, remove the saturated foam and install a new seal. I really need to be able to watch it under pressure and see if I can find a drip. Right now all I have is saturated foam, a real fire hazard, and I can't tell where its leaking from.

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igotedache

· #2 · Nov 3, 2013

G`day
Not sure about the S but the R had a similar standard factory leak from the underside of the fuel tank,the fuel pump flange.
No matter how many gaskets you tried it would inevitably leak again! IMO the tank distorted when the fuel pump assembly was bolted back on due to the thin flimsy steel the tank was pressed from.You could try a new gasket? (not familiar with the S) or try your luck at getting the "bolting face" of the tank dead straight,flat even and level then see if that does the trick....
....or a new tank....second hand may have the same issue even tho it looks lovely!
Good luck mate!

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Angrywasp

· #3 · Nov 3, 2013

I pulled the foam off my S tank as I had the same problem. Then the new gasket wouldn't seal either. Ended up using some aircraft fuel tank sealant to fix it. Making the fuel pump assembly flex/deform enough to break the seal on our tank isn't that hard of a thing to do IMO.

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cyclecamper

Discussion Starter · #4 · Nov 3, 2013

I understand the seal; I organized the appeal to NHTSA/DOT which caused the recall of the '97 tank and seal.

It might not even leak anymore, might have just when I was pulling the hoses. But I will remove the foam and replace the pump/tank seal.

Can I get new foam to replace it when I'm done?

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Six5

· #5 · Nov 4, 2013

cyclecamper said:
...
...But I will remove the foam and replace the pump/tank seal.

Can I get new foam to replace it when I'm done?

I was under the impression that the foam pads under the tank were only on the "California" models, but maybe not.

My '98 did not have the foam pads.

At any rate, I found these in the micro fiche that comes with the TLS service manual download. They have part numbers. It is just a matter of checking with Suzuki to see if they are still available.

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zippytlsr

· #6 · Nov 4, 2013

Well done Six5.. I pulled the foam off my tank Looooong ago.. made no difference in anything. FWIW. :cheers

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igotedache

· #7 · Nov 4, 2013

Angrywasp said:
I pulled the foam off my S tank as I had the same problem. Then the new gasket wouldn't seal either. Ended up using some aircraft fuel tank sealant to fix it. Making the fuel pump assembly flex/deform enough to break the seal on our tank isn't that hard of a thing to do IMO.

Lucky you i tried that Permatex stuff and some expensive petrol proof sealant they use in the oil and gas industry but none of it helped,Permatex is sticky and non hardening so be careful not to get any around the inside of the tank.

@ cyclecamper:check your fuel hoses as they may have perished and /or there may be a small hole in one of them.
From past experience your outa luck on the recall! 10 years max and the manufacturer is in the clear and there`s no recourse.

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actls

· #8 · Nov 4, 2013

Might be worth a try.

http://www.tlzone.net/forums/help-forum/124689-ring-2-tank-seal-mod.html

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cyclecamper

Discussion Starter · #9 · Nov 4, 2013

Six5 said:
I was under the impression that the foam pads under the tank were only on the "California" models, but maybe not.

My '98 did not have the foam pads.

At any rate, I found these in the micro fiche that comes with the TLS service manual download. They have part numbers. It is just a matter of checking with Suzuki to see if they are still available.

Thanks! I don't know what I was looking at... With what you & zippytlsr say, and based on the fact my Illinois '97 didn't have it, I'm initially going to just remove the foam.

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cyclecamper

Discussion Starter · #10 · Nov 4, 2013

I'll definitely keep the ring-in fix in mind if necessary. I sure don't want to finish my bike just to have it burn to the ground. I wonder whether I can get o-ring cord from someplace like McMaster-Carr here.

Yep, they have everything...

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