XS1100SG Fuel Sender LEAKING

[bikerphil]

Looks like a nice solid safe repair, hope it works out.

[cajun31]

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.

I was wondering about this product and if it will hold up to gas. I know it says it does. If it truly does then it might be an option for minor post repair.

[jetmechmarty]

I was wondering about this product and if it will hold up to gas. I know it says it does. If it truly does then it might be an option for minor post repair.

Regular JB Weld holds for some time and eventually fails. My bike had a JB post repair and I didn’t know until it failed. It took two or three years. I’m hoping for the best here.

[Hydroman]

I rebuilt mine. The original seals around the rivet were bad. I drilled out the rivet and replaced it with a brass bolt and nut. I bought new rubber washers to go on each side. I soldered the wire from the sending unit to the screw head. I put the nut on the outside of the tank. I coated both sides of the washers and the bolt with a gas proof sealer before putting together. That was several years ago. It is still holding. There is a plastic sleeve that goes through the plate. You have to reuse this, or the bolt will be touching the steel plate. It insulates the electrical from the plate.

[jetmechmarty]

There's no gasoline smell in my garage, so it's fixed for now.

[bikerphil]

Well Marty, that's good. I hope it holds up.

Hydroman sounds like he has a decent fix that he posted above, kinda like something that I was thinking of doing.

[Radioguylogs]

Coincidentally, my Venturer started leaking around the sender this week.

I can't tell for sure if it's leaking around the gasket or the the place where the conductor passed through.

I ordered a new gasket to try that first.

[jetmechmarty]

I ordered a new gasket to try that first.

That's how I played it. Part Shark was PDQ.

[cajun31]

I rebuilt mine. The original seals around the rivet were bad. I drilled out the rivet and replaced it with a brass bolt and nut. I bought new rubber washers to go on each side. I soldered the wire from the sending unit to the screw head. I put the nut on the outside of the tank. I coated both sides of the washers and the bolt with a gas proof sealer before putting together. That was several years ago. It is still holding. There is a plastic sleeve that goes through the plate. You have to reuse this, or the bolt will be touching the steel plate. It insulates the electrical from the plate.

curious as to what the rubber washers are made of. Hopefully they won't break down being submerged in gas.

[Radioguylogs]

...Part Shark was PDQ.

Partzilla was not.

I have been waiting 4 days and they haven't shipped it yet even thought their site still reports they would ship it 2 days ago.

I hate the thought of the warm, humid air entering the garage every time we open door. The moisture just condenses in every cool item, and the tank is mostly empty...waiting for parts.

The time I tried Part Shark based on your suggestion, they were fast and the prices were competitive.

[bikerphil]

Yeah I like Partshark too, I just ordered some carb shaft seals and they told me by email within 24hrs that they were on backorder for 3 weeks and asked what would I like to do. They don't just leave you hanging like some other online dealers.

[Radioguylogs]

It took 2 weeks to receive the new gas tank sender gasket from Partzilla, so I pulled the sender out to replace the gasket.

Based on @jetmechmarty's experience, I scrutinized the area where the conductor passes through the plate. It definitely looked suspect on the outside:





The inside had a plastic ring cupped over a rubber gasket. The plastic ring looks cracked:





I am debating whether to fix the outside only, or to gob sealer over the inside and the outside.

I have good experiences with POR 15 coating, so I decided to try their sealing putty:




I ordered it and it should arrive sometime in the next week.

[JonnyO]

I ordered it and it should arrive sometime in the next week.




[/QUOTE]
Looking forward to hearing how it goes. I've use POR in the past, as well.

[jetmechmarty]

I got the JB TankWeld for $5 at Tractor Supply. I bought it online and went to the store and picked it up a couple hours later. I still have no gasoline odor in the garage. If there is, my wife is on it like a hound dog. Thus far, I have a fix.