Triumphrat

cm08 · 01-01-2007, 07:52 PM

I am aware of the recall years back on the senders, but my bike was not in the range and the sensor has been working OK and been leak free until now. Following recent removal of tank for valve adjustment, I noticed after picking up my tank to reinstall, a small puddle of fuel directly from the fuel sender. It seems like it is coming from the potting around the wires. While the leak is still small it is increasing.

I was thinking of removing it and trying to reseal it with fresh epoxy adhesive, RTV sealant etc. (something alcohol and fuel resistant).

Anybody have experience in this area?

Thanks

CM

Robdan · 01-01-2007, 08:50 PM

I have a 2000 Sprint and it started doing the same thing at about 12000K. Before it started leaking, it would give false readings on the fuel gauge. After having the shop take out the old sender, they explained why I had to have the whole thing replaced. After looking at the old sender, I thought at first that it probably could have been fixed with epoxy, sealing the whole area around the leak. The new one cost about $140 CDN. before installation (plus 40 minutes of labour), and now I have had it replaced, I think it was worth it, rather than going the repair route. If you decide to repair yours, let us know how you did it and if it was successful.
Safe riding.
Rob

trotsky · 01-01-2007, 11:28 PM

If you could take a picture of the under tank plumbing when you take it all apart I would appreciate it.

I had my tank off and I have a bunch of tubes that look nothing like the diagram in the shop manual.

Might just be coz mine is a CA version though, but I want to put things back the way they were before I started. Not usre if it was me pulling the tank off or the last service tech who got things looking like spaghetti down there.

Thanks

clockwatcher · 01-05-2007, 12:34 PM

I had the same problem a few months back. I couldn’t pay $120US for a new sending unit without attempting a repair. It cost next to nothing to fix it and has been leak-free for the past 8 months. Here goes:

After draining the tank and removing the sender, I turned the sender upside down in a bench vice, cut away the sheathing around the two wires where they exit the potting and roughed up the area with course sandpaper. I then cleaned the area with electrical cleaner and a rag. I found a plastic lid with a diameter slightly larger than the potted area to use as an epoxy mold. I cut the top off the lid and secured it with tape, mixed up some 30 minute epoxy and poured it into the lid. I spread the wires apart to allow the epoxy to fill the area between. You only need 1/4 inch (3cm?) of epoxy. Anymore and the wires will be smashed against the engine when you install the tank.

Note: As you install the tank make sure the one-way vent valve is positioned vertically. Otherwise the valve will close (as designed) and cause pressure to build up in the tank which increases the change for more leaks latter on.

Hope this helps.

cm08 · 01-05-2007, 01:45 PM

clockwatcher,

thanks for the reply. I'm with you, it doesn't hurt to try and fix it.

I removed the sender yesterday, and to my surprise it had a green cap, which if you go back a few years may indicate that it should have been replaced as part of a recall. So, I checked to see if my s/n was affected and it was not. This was strange because looking at the sender, it looked like it was one of the bad batch. (green cap and potting around the insulation- sheathing).

Something felt "not right" so I took the sender to the dealer who also confirmed by looking at it that it was one of the "bad" lot. He (actually she) was professional and nice enough to check with triumph France and according to triumph France's records the original fuel sender was replaced by another dealer. Thsi explained how I ended up with a bad unit. The dealer has submitted a warranty request, 7 years later, and now I am waiting to see if they give me a new one gratis.

CM

Thefallenone · 01-05-2007, 05:32 PM

Best of luck buddy :-D

Kev

Thefallenone · 01-08-2007, 04:15 PM

Any luck mate?

Kev

cm08 · 01-08-2007, 05:45 PM

Nice of you to ask. No news yet. Seems like the guy making the decision at triumph France was out on Friday and the shops are closed on Mondays. I am waiting for the dealer to call me. They assume Tuesdya, but this is France, so who really knows.

When in Rome.........so in the meantime I made a blanking plate and plugged the hole so I can ride at will. Other than the low fuel warning light coming on, no leaks and all is ok for now.

I am very hopeful as it seems pretty clear the fuel sender was indeed one of the bad batch installed as a spare part. Stay tuned.

CM

cm08 · 01-10-2007, 09:31 AM

Woohoo, Triumph France came thru, with the help of the dealer and the very helpful lady behind the counter (for those of you in the Paris region - Diagonale)

Triumph agreed that the sender,after confirmation by the dealer, that it was part of the defective batch as per the recall.

They Sent me a new sender (grey cap and correctly epoxied) and new gasket at no charge. I would have expected this, but these days you never know. Its already on and I am ready to ride. No more smelly fuel!

So kudos and thanks to Triumph France and the dealer.

CM :-D

Thefallenone · 01-10-2007, 02:17 PM

Good result - well done :-D

Kev