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old rubber and gas leaks

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  • old rubber and gas leaks

    So my '79 special is in pretty good running order now, just got new tires, and is leaking gas...

    I overfilled it once and some came out of the top after it heated up, so I need to replace the seal on the gas cap (it is practically disintegrating). The right side fuel petcock seemed like it was leaking so I got whatever o-ring I could make fit locally and that seems to have stopped that. I still have gas on the right side of my tank a day later though. It definitely didn't come from the petcock after inspecting it, and it seemed like it was coming from the inner part of the tank and running down the edge. I think it has got to be from around the fuel sensor.

    So I have a bunch of seal/gasket questions. I saw someone say that you can go to mikesxs and get part #20-0036 for the gas tank cap. What should be done for properly putting the thing on since it has 2 holes and the gas cap has 3? Does it matter?

    After looking at that page I saw Part #20-0018 which is "sealing washers for tap to tank mount screws." Are these the washers that are on the screws for mounting the petcocks? Can they be used to replace these washers? Mine looked like they have seen better days and I'm a little surprised they aren't leaking (if they aren't leaking).

    If the fuel sensor is leaking, am I just going to have to replace the gasket on it? If it does not currently function, is there any way to remove the unit and just seal the hole, like a full cover/gasket not a permanent mod? I was having trouble finding this in the forums, so I just figured I'd break down and ask.

    Oh, also newbish question: should the gas cap seal prevent gas from coming out if you pull the tank to work on something, or do you just have to empty the tank first?
    It's pronounced "Joey"

    1979 XS1100 Special

  • #2
    The rebuilt kits for the Special petcocks are avaialble on ebay from georgefix, for $29.95 (for both petcocks). Be sure to get the one that includes 2 round rubber valves, 2 o-rings and 1 diaphragm for the Octy. I'm not sure about how to go about replacing the gas cap seal, but it should definitely prevent sloshing when you remove the tank. It probably won't prevent seepage (don't turn it upside down), but moving it around with fuel in it should be fine.

    I would not suggest removal of the fuel sending unit. Replace the seal, and put it back in. It really helps to have that feature, and I would imagine ant future owner (if you ever decided to sell it) would appreciate it if you didn't remove it.
    1980 XS850SG - Sold
    1981 XS1100LH Midnight Special (Sold) - purchased 9/29/08
    Fully Vetterized and Dynojet Kit added, Heated Grips, Truck-Lite LED headlight, Accel Coils, Irridium plugs, TKAT Fork Brace, XS850LH Final Drive & Black SS Brake lines from Chacal.
    Here's my web page devoted to my bike! XS/XJ User's Manuals there, and the XJ1100 Service Manual and both XS1100 Service manuals (free download!).

    Whether you think you can, or you think you cannot - You're right.
    -H. Ford

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    • #3
      The petcock was only leaking between the tank and the petcock, so I really just needed one O-ring which is much cheaper than that kit. Besides my octy is gone. :\

      My fuel sensor doesn't work and the connector on it is broken, so I have no real reason to keep it in. I was gonna hold on to the part in case I changed my mind later or sold the thing, but right now it's not a priority fix for me. Just the tank leaking.
      It's pronounced "Joey"

      1979 XS1100 Special

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      • #4
        Hey Joey,

        There's a big 2" square hole where the sensor plate screws into the gastank! The replacement gasket is available from BikeBandit for about $9.00. To find it, you have to look at the ELECTRICAL sections, and you'll see diagrams showing the sensor plate and gasket, not the gastank diagrams!

        The sensor and plate make sealing it easier, but you could possibly make a plate to go over the hole, but you'll still need a big rubber sheet, Neoprene! Do you know if it's actually leaking THRU the sensor plate, or just around it? IF leaking thru it....the sensor it solder into the plate, could probably seal it with JB Weld ...the long setting kind, not the quick set kind, and then put it back on, even if it's not working! But while you have it off, you could possibly repair it by soldering a new tab/wire onto the contact for it!?

        As for the gasket, it fits inbetween the parts in the cap, you unscrew the innards, and then it fits in there, see photos below, old and then new!




        T.C.
        T. C. Gresham
        81SH "Godzilla" . . .1179cc super-rat.
        79SF "The Teacher" . . .basket case!
        History shows again and again,
        How nature points out the folly of men!

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        • #5
          Jeez, could you pick a rustier cap? I literally went outside with a flashlight to make sure mine didn't look like that. (Yes, even though I had already looked at it before and knew it wasn't.) I'll have to pull the tank again to see exactly where the leak is coming from, but I guess I'll just keep the sensor on there...maybe even fix it inspite of my laziness

          Now to start digging on cracked side panel repair...
          As always, thanks for the info guys.
          It's pronounced "Joey"

          1979 XS1100 Special

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