Triumphrat

txsport06

Adding to the "I'm an idiot" comment from my other post. So I'm unscrewing the plastic tank fittings so I can replace them with the Team Triumph metal ones. Got the 19mm socket wrench and a metal bar for leverage, and the first one (the white one) came off without a hitch. The red one starts to turn okay and then CRACK! It breaks flush against the tank. F*CK!!!

I know that someone had a thread about this same type of thing, but I did a bunch of different search terms (plastic, fuel fitting, broke, tank, drilled, etc.) in a bunch of variations but couldn't find it.

The final answer is to drill out the plastic, right? Whoever did that, could you please tell me what size drill bit you used and a bit more detail about your obviously successful effort?

Thanks. SONOFA...

Joe-Dirt

There is a thread in the modification/workshop forum on page 3 about this. I suggested an easy-out, but someone said that wouldn't work on the fittings. You might try using a small coping saw blade, and holding a shop vac to catch any debris, make some cuts (but not deep enough to get into the tank threads), and then pick out the pieces with a tiny screw driver. :wink:

Catenaccio

txsport06,

This is probably not what you want to read, but I just had the same problem with my S4. I called Freedom Cycle in Reno, NV and was told that it takes a special Easy-Out like tool to remove the fittings from the tank. The tool was about $60 from Mac Tools.

I opted to send the fuel sending unit to Freedom Cycle. They repaired the fittings, sent me new aluminum male ends for the quick-connects, and replaced the fuel filter at no charge as this was a recall issue.

Freedom Cycle did this without knowing me and totally from a phone call. I paid shipping both ways and bought a K&N filter just to throw a little money into FC's coffers. If you are anywhere close, give them a call.

They're on the net at http://www.freedomcyclereno.com.[addsig]

txsport06

Thanks for the replies, folks (yeah, I was doing a search in the wrong forum).

Well, I tried to drill the fitting out, but was worried about scoring the threads, so I gave up for the night. This morning, I took the tank to my local bike shop (Fairfax Cycles--they're great, so I'll give them a plug). Kyle in their shop took a tiny ice pick type of tool, toyed around with the fitting for about a minute and then POP!--the entire chunk of plastic threading popped right out. Unreal.

So now I need to clean the threads and then work the metal fittings back in. Again, I'm hoping that I didn't screw up the threads last night.

I'll probably buy a new fuel filter in the event some of the plastic shavings made their way into the hose.

Thanks again for the advice.