Alright, hoping someone can help me out here. Have two problems 1. Have a 2003 6 Gen gutted the fuel tank so I could have it repainted, after someone backed into my bike. no matter what I do I can not get it to stop leaking from the fuel pump base, have put in new gasket, followed the service manual, on how to install. No luck, always leaks from the rear of the base( more like flows). 2. When the bike hit the ground it snapped the threaded stud from the headlight housing, the housing itself was not damaged would prefer not to have to buy a new housing just cause of the stud. Anyone know how to remove the old one and replace it. Thanks in advance.
Good eye Stosh. If that is a broken stud, that right there could be the cause. Gasoline will easily leak where other liquids will not so the slightes break in a seal will be very noticeable. I don't know if you will be able to fix that broken stud with any tools that the normal person might have in his garage. Unless you use Duck Tape JK on that.
That absolutely looks like a broken/missing stud. Without it the tension is asymmetrical. Not good for sealing off liquids. Maybe it got pushed in somehow? Mounting studs into plastic usually have an odd shape or large base cast inside the piece they are attached to. I would drill in increasing sizes until I could epoxy in a new stud. Jose
Ya'll are correct the stud is snapped. The stud was like that before I took the tank apart. At the time of tear down it did not leak. From what I can tell it had been that way for a awhile. I do have another tank that I waas thinking about taking a stud from and reusing it on this tank, do not know how to do that as of now, but have a welder and not much on common sense. It seems to me that because the base sits on the stud ring and not flush with the tank, the seal rides higher than it should. Thanks for the quick replies. This site rocks!!!
This may be a no brainer but welding equipment and gasoline fumes from the tank = disaster. Be careful.
You CAN weld a gas tank, but you have to wash with a couple different products and leave site for a few days. Alternately you can wash and fill with water while you work. Hopefully you are dealing with a press fit stud that you can punch out and replace easily. If not, then you could also consider a closed bottom rivnut with a silicone washer and some fuel resistant sealant. To do a rivnut, you would drill out the existing stud. Then put in the new closed bottom rivnut and get/make an appropriately sized silicone washer. Cover top and bottom of the washer with sealant and fit over the back of the rivnut (inside the tank). Then you put on a backing aluminum or SS washer over the silicone one. When you crimp down the rivnut, it will flare above the backing washer and crush down on the silicone washer. Let it sit for a few days and the stud should be fuel tight. Jose
The stud is just pressed in and should come out pretty easy. The mounting base where the studs are is tacked welded to the tank. Little time and some effort should bring it back to new. I still don't believe the stud is the issue, as I said the stud was snapped when I pulled the tank from the bike, and up to that point no leak. Seems more like an install issue. Thanks for all the help. Any ideas on the headlight fix?
That stud in your lights is probably place in therebwhile the housing is injection moulded. Maybe, carefully, using vise grips, see if you can remove that stud. It might be threaded inside that plastic. Once it is out take it to an automotive hardware store or a mechanical fastened supply shop and see what they may have. Auckland Granger has many different types pf fasteners.
It much good ole Canadian fresh air. Unfortunately here in Chilliwack, that is masked by the aroma of liquid cow shit which is plentiful here. Back to the topic at hand.
First you can weld a gas tank by filling it with argon, which is heavier than air and displaces it and fumes. now these are welded in on my tank and should be a no brainer to tap it out and put another in then using a oxy/acetylene torch and some brazing rod or silver solder. use lots of flux. down side is the paint will be f*cked where work will be done. use low torch heat and lots of time. your brazing rod or silver will flow always to the hottest object, so ensure the stud is hotter than the tank. better fix is a new 6th gen tank is only about 250$ so I did not even fix mine when my bike got backed into. Plus they come painted in all the stock colors.
