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Thread: Fuel leak and tank removal

  1. #1
    Baby Twin
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    Fuel leak and tank removal

    Hi I have just posted a hello in newbies after joining knowing that I may need help in the future but didn`t realise it would be half hour later !. On the way back from collecting the bike I could smell fuel but didn`t think too much of it as it didn`t seem too strong but I`ve just gone to my van to look at bike and the smell was really strong and on inspection I found petrol leaking down onto the chain.
    I took sides off / seat off and lifted tank to which I found what looks to be the breather pipe leaking ? I did a quick search on here and came across this thread Fuel leak from tank pipe and I`m guessing mine has the same problem. Luckily I have a 25l petrol can so I`ve drained the tank for the moment.
    So what I`d like to know is how do I remove tank ? as on my gixxer once unbolted everthing just unclips but this appears to have things bolted to it. Has anyone else that has had this problem got any pointers for me ? and does anyone know what size pipe I need to replace the perished one ? 8mm ? Is it a pretty straight forward job ?
    A pic of the leak and bolt , Any advice will be gratefully received

  2. #2
    Baby Twin
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    From what I Remember the tank is pretty straight forward to remove.
    Remove the 2 bolts at the very front and raise the tank.
    That bolt on the bottom is a banjo type fitting and should come out easily (don't lose the washers)
    2 breather pipes connect to a small block on the right side which just pull off.
    Then unolt the hinge assembly at the back of the tank.

    There is a link in the 1st post here to some suitable pipe
    Leaking fuel tank vent pipe

  3. #3
    Baby Twin Angeldog74's Avatar
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    Hi I had a similar problem- inside your tank there are two breather pipes and over time these deteriorate it's just a matter of dropping the pump out of the tank and replacing the pipes....job done ...little tip buy the right clips as I tried using jubilee clips and the clearance between the pump and the tank flange make it virtually impossible. I ended up doing mine three times before I learnt my lesson and got the correct hose clips .... Also your pipe needs to be graded for submersion in fuel otherwise the exterior will deteriorate again and your doing it again good luck

  4. #4
    Baby Twin
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    Cheers Lads, Yea tank came off easy but when it came to the pump all was ok until one of the bolts snapped off ! I tried cutting a groove in the thread and using a screwdriver but that didn`t work ? Any suggestions ? On the plus side it is defo that pipe as bits of came out with the pump.
    I`ve read online that it would be ok with one missing bolt but I don`t really share their confidence with that one ?

  5. #5
    Baby Twin Angeldog74's Avatar
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    Ooooooohhh bet that's frustrating!! It probably would be ok for a little while but I think I'd be drilling it out ...patience :/
    Have you tried spraying loads of WD on leave for ten mins re-apply (I'm sure you get the idea)
    Why does this always happen when the suns out? Good luck

  6. #6
    Superbike Twin RSV 69's Avatar
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    Look on youtube for a guy named "del boys garage".

    He shows loads of video tips on maintaining your own bike including how to remove a fecked bolt with a center punch

  7. #7
    Baby Twin
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    Thanks for the advice, I spoke to the garage I usually take my car to and he sounded optimistic that he could remove it or if not he knows a machine shop (that happens to be next door to him) that should be able to do it.
    I`ve been applying wd40 since last night so hopefully this will help him I`m going to pop in there tomorrow lunch time and I`ve ordered the new pipes so should (fingers crossed) be good to go by the weekend.

  8. #8
    Baby Twin
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    Quote Originally Posted by Angeldog74 View Post
    Hi I had a similar problem- inside your tank there are two breather pipes and over time these deteriorate it's just a matter of dropping the pump out of the tank and replacing the pipes....job done ...little tip buy the right clips as I tried using jubilee clips and the clearance between the pump and the tank flange make it virtually impossible. I ended up doing mine three times before I learnt my lesson and got the correct hose clips .... Also your pipe needs to be graded for submersion in fuel otherwise the exterior will deteriorate again and your doing it again good luck
    I`ve bought the pipe from the 1st link, its got a 14.5 od so would these clips be what I need ? 10 PCS Fuel Petrol Pipe Hose Clips Silicone Clamp Low Pressure Air Spring Type | eBay
    I will look locally though as I only need 2 not 10.

  9. #9
    Baby Twin Angeldog74's Avatar
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    Yeah those are the ones ....on one of my first rides out after picking up my mille I was stood at the counter in the local petrol station waiting to pay and to my absolute horror out of the window I could see fuel literally pouring out onto the hot exhaust !!! Aaaaargh to be honest in the first month of ownership I had quite a few niggles with her but it's forums like this one that helped me get through them or I may of been back on a blade by now.....stick with it pal they are special bikes once you get them right
    Ride safe

  10. #10
    Baby Twin
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    Ps bud nearest dealer is aprillia in canturbury.. Robinsons foundry!! They good but well expensive!!! Go to hern bay ... ( robinsons brother.. Smaller company .. But lot cheaper!) malcom will help u out with ur future millie probs.... And you will get som lol!!!
    Last edited by Chris millie; August 27th, 2014 at 12:57 PM.

  11. #11
    Baby Twin
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    Quote Originally Posted by Chris millie View Post
    Ps bud nearest dealer is aprillia in canturbury.. Robinsons foundry!! They good but well expensive!!! Go to hern bay ... ( robinsons brother.. Smaller company .. But lot cheaper!) malcom will help u out with ur future millie probs.... And you will get som lol!!!
    I know them over at Robinsons as before this bike my last 4 bikes have been Gixxers the last one from them I bought a new 750 in 2010 but sold it last year and ended buying 2 older 750`s (one track and one road) and then my van to cart the bike around. They did loads of work on my 750 inc remaps after I decatted it.
    I`m not familiar with the one in Herne Bay but think I may need to the more I learn about the Mille`s !!

  12. #12
    Baby Twin
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    How'd you get on with the repair? I've just ordered the same fuel hose to replace my pipe. Nothing leaking yet but would rather do it now than wait for it to fail. Got the Gen1 with plastic tank, might need to get some sealant as well lol.
    Andy

  13. #13
    Baby Twin
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    I`ve not done it yet as the tanks at the garage I use for my cars hopefully getting the snapped bolt removed, I`ve got the hose and I`ve ordered the clips which should arrive Friday so as long as I have tank back I`ll get it all back together on Sat.
    I`ll let you know how I get on ! Mines a metal tank but I have read about the problems people have had with the plastic tanks.
    I was googling the problem today and come across this fix The Dreaded Fuel Pump Plate Leak not sure its a good idea though ? attachment.jpg

  14. #14
    Baby Twin
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    That's an interesting read, will do some more searches. Hope yours goes ok, keep us all posted.
    Andy

  15. #15
    Baby Twin
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    Well no joy with the garage drilling it out and he`s broken a drill in it so not sure what to do now ? I found a local breakers selling a tank so I bought it but its a plastic one off the R model and from what I read it will fit but my fuel cap etc won`t so its going back.
    I am now thinking of putting it back together with what bolts it does have and then putting a thin seal of this Granville Petro Patch Putty Fuel Tank, Gearbox Crank Case Repair 50g | eBay all round the bottom of the pump before refitting and filling ? As the existing bolts should work and this would seal any gaps if any ?

  16. #16
    Baby Twin
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    Looks like that should do the trick. I once broke an easy-out bit in a bolt I was trying to extract!! Ended up taking it to an engineering shop, they did it & gave me a replacement bolt. All for a couple of packs of biscuits & a fiver in the coffee boat! Lol. My hose & clips will be here tomorrow, will prob wait until early next week to fit them as I've a charity ride this Sunday & don't want to be without bike incase I have any problems.
    Hope your repair goes well.
    Andy

  17. #17
    Superbike Twin
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    rusted bolts come off with vinegar (yes, straight vinegar) or with... water! in this case vinegar would have been more suitable. if you still have a bit of bolt hanging out cut a slot again in it and let it sit for a day or so with some vinegar, you just have to moisten the bolt.

    if now the bolt is flush or nearly flush a bench drill will do wonders! repair the thread with helicoil and (almost certainly) some epoxy...

  18. #18
    Baby Twin
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    All sorted now with a replacement tank though that did not come without its own issues....Anyone else swapped metal tank for plastic one ? if so is this normal ? .....

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