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Daytona Deliberations For owners and riders of Daytona 900, 955, 1000 & 1200

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Old 12-07-2012, 05:13 PM   #1 (permalink)
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Gas leak

I put the T595 in my parents garage since I do not have a garage and Its not staying outside all winter. They called me a couple days ago saying their garage smells like gas and there's a puddle under the bike. Okay...it didnt leak before, maybe a hose came loose from the previous weekends riding. I was rained out from work today and my parents were both at work so I figured it would be a good day to go look at it. Sure enough a puddle under the bike and the smell of gas in the air, hmmm. Pushed the bike to the tool shed and started taking the plastics off. Get to the seat cowel, all bolts come out fine except one, the one that bolts to the tank on the left side. Finally get it out and to my surprise see gas in the hole where the bolt goes on the tank. I have no clue how I would go about fixing this, I did drain the tank and remove it from the bike. Any thoughts or ideas?

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Old 12-07-2012, 05:24 PM   #2 (permalink)
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You're not the first - and probably not the last - to have this problem.

Did it have the correct screw in there?
Either wrong screw (too long) or was over-tightened and cracked the plastic

You can try making a patch on the inside - remove the pump to access, scour up the surface to key and clean thoroughly then apply a patch using fuel resistant epoxy (JB Weld will work) and allow to dry completely before re-filling.
I would suggest coat of epoxy with a thin plate over that; allow to dry then another coat of epoxy over the whole thing.
If the nut is spinning free, that is another problem - you might have to try to epoxy that in place too.

That one looks quite the mess though - was it like that or dd you make all those gouges trying to get panel off?
You might end up having to replace tank.
If you do, note that yours is a 10-bolt tank - needs to be off 97/98 models - if you end up with 99-01 tank, you will need the pump to suit.
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Old 12-07-2012, 05:41 PM   #3 (permalink)
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Is it possible the gas trailed to the bolt from another source? I had the quick release connection on my 955i fail twice. Both times it went unnoticed until the bike sat overnight. I'm just glad I didn't burn the house down!
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Old 12-07-2012, 06:03 PM   #4 (permalink)
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Thanks for the quick reply's. Decosse, I used the same bolt that was in there when I bought the bike, the other side came out just fine so Im sure its the correct size bolt. The gouges there were not there before and were done by me with a bar trying to get some pressure on the bolt to get it out. I have ran that bolt back in and out of the hole and it is still good. But, it was leaking before I pried off of that so it could have just been over tightened the last time which is why it got stuck in the first place, I will try the JB weld, luckily my dad keeps a lot of that around lol.

Motovation, I checked the entire tank once I got it off looking for a small trail or drip, especially around the fuel pump connectors, and I didnt see anything.
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Old 12-07-2012, 06:22 PM   #5 (permalink)
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Again, will have to apply the patch from the inside

I had leak through one of the vent tubes through the tank, from filler neck down to the nipples on left side - that was about 5 years ago - JB Weld still holding solid!
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Old 12-07-2012, 10:19 PM   #6 (permalink)
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Quote:
Originally Posted by DEcosse View Post
Again, will have to apply the patch from the inside

I had leak through one of the vent tubes through the tank, from filler neck down to the nipples on left side - that was about 5 years ago - JB Weld still holding solid!
that JB weld is good stuff...I couldn't tell you how many times we have used in in a pinch, just as a temporary repair, and then never got around to fixing something properly because the JB Weld worked so good. I am going to take the tank apart tomorrow, try to find the leak and see what I can do with it.
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Old 12-10-2012, 04:10 PM   #7 (permalink)
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I have two tanks and they both leak on the right side in the same place. I bought the second tank partly due to the leak in the first. I would not use JB weld unless it is the gas resistant type. I had used JB on a tank only to have the weld dissolve in the fuel and the leak spring anew. I went to Advance Auto and got the tank repair material and have not had any issues. Going to have to do the same thing you are doing to repair from the inside of the tank.
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