XS1100SG Fuel Sender LEAKING

[jetmechmarty]

I went into a garage filled with gasoline fumes this morning. Upon lifting the tank, I found the fuel sender unit assembly is leaking. I hope it's the gasket, but can I be so lucky? I've had this bike since 2003 and have never futzed with it. 3H3-85752-00-00 is NLA. So, I'm hoping someone reading this has repaired a leaking sender, so I don't have to reinvent the wheel. Meanwhile, I'll order the gasket. Anyone? The bike is a 1980 Special. The sender turns the red light on as opposed to the standard fuel gauge.

[cajun31]

That unit is simply a solid piece of metal other than the bolt holes that the bolts go through. If it is original and the gasket has never been changed then that is what I would have to suspect is leaking. I have actually reused all of the gaskets on my bikes. They can get hard and crack over time. I know you know the part number of what you need and it looks to be available from Partzilla 2H7-85753-00-00.

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[jetmechmarty]

That unit is simply a solid piece of metal other than the bolt holes that the bolts go through.

Thanks! I'll get a gasket coming.

[bikerphil]

It can leak where the wire goes thru to the thermistor, there is a fiber washer there. I had this happen but just replaced the whole unit with a donor from an extra tank.

[jetmechmarty]

It can leak where the wire goes thru to the thermistor, there is a fiber washer there. I had this happen but just replaced the whole unit with a donor from an extra tank.

That's what I'm afraid of. Based upon eBay asking prices, I won't replace it. I'll fix it or replace with a blank plate.

[bikerphil]

Yep, there is a rivet holding this wire terminal together. It may be repairable. A few pics...

[jetmechmarty]

Now that the tank is empty, I can see the leak path is through the sender. So, I'm going to have to come up with a fix.

[bikerphil]

I'm going to think about a way to repair this too. Maybe drill out and use either a bolt or a large pop rivet with a new nylon washer, which should hold up to gas.

[DiverRay]

Maybe smear some fuel tank sealer over the inside of the sending unit. Sealed from the inside, and no more leaks.

[oldyam80sg]

Hylomar is great for dealing with gas leaks.

[LAB3]

You might want to try some of that putty they use to patch leaky gas tanks, you should be able to find that almost anywhere. Also put some fresh fiber washers on the mounting screws, you can get those at the local hardware store. They're usually sized in english but if you find one that's just a tad small a small piece of rolled up sandpaper will quickly reem it out to size.

[kboehringer]

Marty,
I'll take a look this weekend. I may have one I would send on over to you.
I'll check this weekend.

KURT

[jetmechmarty]

Marty,
I'll take a look this weekend. I may have one I would send on over to you.
I'll check this weekend.

KURT

Thanks Kurt. Mine is functional, so if I stop the leak I'll drive on.

I bought this stuff to fix it. $6 If it does what it says it's supposed to I may not ever have to futz with it again. I just received a tracking number for the gasket. Maybe I'll have it fixed middle of next week. I'll update.

[bikerphil]

I've been fooling around with this repair but with one accidental spark from a short and, well you know the rest. That fuel light isn't that crucial. I remember now a while back when mine started leaking, I made a block off plate from an electrical box cover and ran with that. A year later, I ran into a replacement. I don't think it's worth the risk rebuilding.

[jetmechmarty]

I used the JB Tank Seal. There’s nothing left but the leak test. The bike is still on the lift with the wheels off.