Major gas leak

Whiteduramax · #1 10-07-2009, 01:56 PM

Decided to ride the bike back to work from lunch. Backed her out of the garage and started her up. Was buckling on the helmet when I looked down and saw gas POURING from the fitting that comes from the underside of the tank. Turned it off and the hose has a banjo fitting and it was real loose but couldn't figure out how to tighten it. Was in a hurry to get back to work so pushed her back in the garage and will look at the SVC manual when I get home tonight, just thought I'd plug the brilliant minds on this board before tearing into the manual. All I have to do is turned the ignition on and even without starting her she starts pouring the gas.

She's a 2000 Road King Classic.

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DGlide04 · #2 10-07-2009, 05:31 PM

EFI or carb? If it is EFI, the pouring you saw was the result of the fuel pump kicking in and doing it's thing. If it is a carb, it shouldn't leak that fast.

Whiteduramax · #3 10-08-2009, 06:52 AM

More to the story. Friend showed me that it was a quick disconnect going from the hose to the tank. Disconnected cleaned the hose end and re-connected and it's worse. Is it the hose that's bad or the quick disconnect fiiting?

n8dc · #4 10-08-2009, 07:48 AM

Its the fitting . If its the newer style that you slide the outside up on the chrome part and insert the lower black part ? There is an O-ring that seals the outside of the fitting to the lower black fitting when its plugged in . That o-ring is either gone bad (most likely) or has a cut or a chunk out of it.. PM me your email.. I have a sketch and part numbers for the o-rings. I designed built and programmed one of the assembly machines for that part and worked where the part was made.. There was a real early version that was made by someone else but it wasnt a true quick disconnect and the later version is. Also on some of the early systems they had 2 fittings not like the 1 on the later models .

jharanin · #5 10-08-2009, 08:01 AM

Have you had the tank off recently? the hose they use for FI is a little more brittle than old neoprene. I was warned that heat from the motor combined with pulling or twisting some causes the line to crack and that may be what you're seeing...just an idea.

Whiteduramax · #6 10-08-2009, 09:47 AM

Dave, Thanks. I sent you a PM. Can this fitting be repaired? I have tons of commercial grade o-rings of different sizes. Anyhow if not and I have to remove the fitting will the gas run out of the tank? I will snap a picture at lunch if needed.

Whiteduramax · #7 10-08-2009, 09:49 AM

Quote:

Originally Posted by jharanin

Have you had the tank off recently? the hose they use for FI is a little more brittle than old neoprene. I was warned that heat from the motor combined with pulling or twisting some causes the line to crack and that may be what you're seeing...just an idea.

Thanks for the reply j but no I have not had the tank off. Really a strange deal to be riding one day with no mishaps and then park it and a day later it's got a bad leak. It's really not a leak it's more like a blow out. As soon as the fuel pump kicks in, it's gas all over the place.

Whiteduramax · #8 10-08-2009, 02:22 PM

Quote:

Originally Posted by n8dc

Its the fitting . If its the newer style that you slide the outside up on the chrome part and insert the lower black part ? There is an O-ring that seals the outside of the fitting to the lower black fitting when its plugged in . That o-ring is either gone bad (most likely) or has a cut or a chunk out of it.. PM me your email.. I have a sketch and part numbers for the o-rings. I designed built and programmed one of the assembly machines for that part and worked where the part was made.. There was a real early version that was made by someone else but it wasnt a true quick disconnect and the later version is. Also on some of the early systems they had 2 fittings not like the 1 on the later models .

Dave, I pulled the oring at lunch. It does has some stress cracks and I do feel that is the problem. I've sized the oring with my oring inventory and have nothing that size. That is unless the one I pulled from the bike is all swollen up.

Whiteduramax · #9 10-09-2009, 09:27 PM

The latest. If not for N8DC I would still be wondering. Anyhow I had to fix both the main fuel line and the return line by installing a new o-ring. N8DC (dave) supplied me with great info and pics. I will at a later date post these pics with deminsions and give Dave all the kudo's with hopes it will help the next guy/gal that has a major fuel leak.

Thanks Dave

03dragonRK · #10 10-10-2009, 12:06 PM

Whiteduramax,

I look forward to your post with the o-ring info as I have had to replace the o-ring in my fitting and ended up purchasing a new fitting in order to get the o-ring since HD does not sale only the o-ring.