TLR Fuel Pump Gasket and Cover

I'd recommend that you stick with the stock Suzuki fuel pump gasket, if you are going to use a gasket. Others have reported that they have had good success with a large o-ring. You would have to search for that, as I do not remember what size they were using. As for the rubber boot around the fuel pump, I took mine off and have not had an issue with it being removed.

Many thanks Rickysnicker, l will have another search for the o ring method.
I did find on tlplanet someone that used a viton seal combined with an original seal to some success.

Post #4 in the thread linked below has a link to the Viton O-ring many have been using.

Gas leak


As Ricky noted, the rubber fuel pump cover is not necessary. I've been running my TLR for ten years without it. No problems.

Vin said:

Many thanks Rickysnicker, l will have another search for the o ring method.
I did find on tlplanet someone that used a viton seal combined with an original seal to some success.

Click to expand...

I did the Viton thing and have had no issues with it. I followed Six5's instructions. However, it i had to do it again, I'd try the o-ring trick.

Rickysnicker said:

I did the Viton thing and have had no issues with it.

Click to expand...

I also did the Viton + genuine gasket, after a miserable failure with an aftermarket gasket.

The boot is basically helpful if you are riding very vigorously on the last bit of fuel in the tank, it's a surge baffle. Otherwise you'll never notice the difference.

Thanks for your advice guys it's much appreciated👍
Anyone on here use a UK based supplier for the viton o rings?

Not had much luck with imperial size ordering but l have found a supplier with a viton o ring 102mm x 112mm x 5mm

Imperial exactly is 101.60mm x 111.12mm x 4.76mm

The difference is obviously slight but just want to check before ordering if anyone can advise?

Cheers Vin

Vin said:

Not had much luck with imperial size ordering but l have found a supplier with a viton o ring 102mm x 112mm x 5mm

Imperial exactly is 101.60mm x 111.12mm x 4.76mm

The difference is obviously slight but just want to check before ordering if anyone can advise?

Cheers Vin

Click to expand...

I did just the Viton O ring after wasting money on a original Suzuki seal that still leaked.

Vin said:

Not had much luck with imperial size ordering but l have found a supplier with a viton o ring 102mm x 112mm x 5mm

Imperial exactly is 101.60mm x 111.12mm x 4.76mm

The difference is obviously slight but just want to check before ordering if anyone can advise?

Cheers Vin

Click to expand...

Hi again guys, ls it possible that someone that has done the viton o ring mod please confirm the thickness of the oring that they used in millimetres please. Just having a little issue trying to find something local in imperial.
Regards Vin

DaveFields said:

View attachment 66125

Click to expand...

The pic I attached is what I used

Many thanks DaveFields 👍

Vin said:

Many thanks DaveFields 👍

Click to expand...

I forgot to mention ordered it from Amazon had it next day.

you don't use the OEM gasket plate along with the Viton right? just the Viton between the fuel pump and tank surface? ... Stupid question but want to be 100%. I noticed the length of the bolt may press against the sealing surface if the OEM plate is not used. Gas was all over trying to reuse the original gasket. PITA. Thanks to this Dave .... saved me I had to do this asap and the Amazon listing was gold so appreciative.

you would have to search for that, as I do not remember what size they were using.

Vin said:

Hi All, Is the fuel pump gasket only available from suzuki? Showbox jiofi.local.html tplinklogin
Also is the fuel pump cover necessary? I guess Mr suzuki added it for a reason but wondered if anyone has omitted it with any luck/problems? £56 for a bit of rubber is a bit extreme as is the £33 for the gasket!
Cheers in advance Vin

Click to expand...

Worked great with just the oring and no oem gasket plate required. Torque to 3nm. Good to go.

If you are asking me, yes, I used the stock gasket along with the viton.

I am just saying for others who find this thread in the future I did it like Dave Fields with the oring referenced above only. I didn’t need the oem gasket also. Works great. The oring is thick enough to compensate for the screw length. I torqued to 3nm. All good.

Driift said:

I am just saying for others who find this thread in the future I did it like Dave Fields with the oring referenced above only. I didn’t need the oem gasket also. Works great. The oring is thick enough to compensate for the screw length. I torqued to 3nm. All good.

Click to expand...

Driift, did you install this O-ring fix on a TLR or TLS fuel tank?