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Old November 24th, 2019, 04:25 PM   #1
Tylerscott86
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Fuel leak

So took my bike out for it's first official ride after getting her going today. Got a little low on fuel and stopped to fill her up. Now it's leaking from some where. Wasn't leaking when I put the initial gallon in there after all my work. So now I'm sitting at the gas station waiting for it to reach a level where it's not leaking so I can get back home. It's not coming from the petcock. Looks to be from a seam in the tank. Can't really tell though. Any thoughts?
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Old November 24th, 2019, 05:19 PM   #2
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Did you have hole in tank from fairing bolt at front? That's high up, so tank needs to be at least 3/4" full for it to leak.

Leaking petrol can be dangerous...

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Old November 24th, 2019, 05:58 PM   #3
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I don't think I did but I just let it sit until it stopped leaking completely. About half a tank now. I wiped up any fuel I saw left on the bike. Them drive home. I'll have to tear into it and see what's up I guess.
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Old November 24th, 2019, 07:24 PM   #4
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Did you unbolt the fairing side panels from the tank?
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Old November 25th, 2019, 05:24 AM   #5
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That's the plan once I get a free day. Working 2 jobs leaves little time. But when I bought it, it was in pieces so the fairings have been put on recently. Guess either I did it putting it together or the PO did it and I found it.
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Old November 25th, 2019, 08:18 AM   #6
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Read through this section - https://faq.ninja250.org/wiki/How_do...l_tank,_etc%3F
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Old November 25th, 2019, 06:28 PM   #7
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Mine was like that too.

PO has installed wrong screws and made the hole top right.

Get yourself a 6mm set screw and some gaska-cinch or other fuel resistant glue. There are many out there. Hopefully you have a 6mm tap as well. We ran the tap through so the the tank itself had the proper threads, make that thread, most likely one. Put sealant on the set screw and run it in. ensure that it is just proud of the tank itself.

Just to be sure put more sealant around the outside of the set screw and between the plate and the tank while keeping it off the threads of the plate itself.

If worried put the tap in and out of the plate.

After the appropriate time for your glue put some gas in the tank if it was empty, no need to fill it, just lean the tank over to the leaking side and see if it leaks.
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Old November 27th, 2019, 09:29 PM   #8
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Quote:
Originally Posted by Fixit View Post
PO has installed wrong screws and made the hole top right.

Get yourself a 6mm set screw and some gaska-cinch or other fuel resistant glue. There are many out there. Hopefully you have a 6mm tap as well. We ran the tap through so the the tank itself had the proper threads, make that thread, most likely one. Put sealant on the set screw and run it in. ensure that it is just proud of the tank itself.

Just to be sure put more sealant around the outside of the set screw and between the plate and the tank while keeping it off the threads of the plate itself.

If worried put the tap in and out of the plate.

After the appropriate time for your glue put some gas in the tank if it was empty, no need to fill it, just lean the tank over to the leaking side and see if it leaks.
Something along these lines is the plan. Thanks for the directions. Just gotta find the time now.
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Old November 28th, 2019, 07:46 AM   #9
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MOTY - 2018, MOTM - Nov '17
As additional safety measure, you can fill gap between tank and plate with strong 2-part epoxy. This will seal plate so anything getting past threads won’t go anywhere.
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Old December 9th, 2019, 02:37 PM   #10
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When I purchased my 250 I had no clue about the fairing bolt-gas tank problem. Filled up with gas on the maiden ride home and found out the hard way as half my body was soaked in fuel by the time I got home. Plus it was only about 38F outside.

I JB-Welded my tank holes and they are holding up just fine!
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