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On my Tiger with 2200 mi I had fuel leaking on a hot day (Have a thread under 'Fuel...do it stink' in the Tiger section)
Some time back I had received a set of metal fittings from GREAT BAY Triumph so thought I could just switch out the fittings.
After removal of the quick release, the lightest turn of the fitting in the tank snapped it off with about a 1/16 standing proud of the threads.
It seemed soft enough so I tried to 'unscrew' the broken threaded portion only to end up with a rough plastic collar in the threads that seemed to work harden and get stuck even harder.
On the second fitting I was more careful, lightly twisting back and forth detecting the movement only to have it snap off clean.
Here is my solution - if the fitting snaps off, before trying to hog it out of the hole - heat up a screwdriver large enough that when hot pressed into the broken part will leave two slots. Hold the screwdriver in place until cool and slowly unscrew the fitting. Mine came out pretty easy.
On the hole with the messed up plastic bits wedged in the threads, I put a dab of grease at the back of the hole (to catch particles) used a dremel tool with a wire brush and 'combed' out the threads, Then I restored them with a pipe tap. (1/4 x 18 NPT)
After, I used a pipe cleaner I had wrapped abound a wire (shirt hanger size) coated lightly with grease and cleaned out the fuel hole with my 'drill'.
All done with the tank in place, New fittings installed, the key cycled a few times to prime the fuel pump and I was rewarded with a running bike ...no more leaks!
Hope this helps.
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