2003 Ultra Classic. Several years ago the fuel pump was serviced and when i went to pick up the bike, it was leaking fuel from the top of the tank. Two more trips to the service department and it finally stopped leaking. It started leaking again and i realized that several of the screws holding the plate to the top of the tank are stripped. Harley doesn't seem to have a solution for this issue. Any suggestions??

 

If you don't have to look at it (like it's hidden) use larger screws?

 

Rivnut/Nutserts? If you paid a dealer to fix it I would certainly be pursuing them for the repair.

 

Sounds like this was repaired :several years ago".

First, while not certain, I find it hard to believe it is metal to metal - is there some sort of a gasket there?

If the screws are stripped - get new screws.

 

I would go back to the H/D dealer that did the work but it was several years ago and they would probably claim that I did it. There is a gasket there but they over-tightened the screws so much (to get it to stop leaking I'm guessing) that it bent the rim of the tank. I've managed to straighten that out as much as I can. I thought about drilling and tapping to a larger size, but the one time use replacement screws from Harley only come in the original size and have a self-sealing ring on them that compresses when tightened.

 

Go to the hardware store and get some short self drilling sheet metal screws a little larger?

 

New tank, helicoils, drill/retap with larger screws. Don't forget that each screw has a plastic gasket on it.