Gas leak from Gas Level Sensor

[dsw]

Hi,

I've sprung a leak in my gas tank - from where the gas level sensor is bolted to the inside of the tank. I've replaced the o-ring and even just got a new o-ring and sensor. All to no avail - gas tank still leaks like a sieve. Wondering if anyone else had run into this problem or had found a solution.

Thanks!

[chris]

I havent sprung a leak, but you should be able to use any gasket sealer thats rated for fuel. I cant remember the good one off the top of my head, but they have to be rated specifically for fuel to work

[maddog53]

Hi new to this forum ,however I have written volumes on the problem of leaking fuel tanks in another forum, I have an 08 SD purchased in late 09, the bike was then stored with "pump" high test, what I didn't know then was the content of the fuel in the US contains at least 10% ETHANOL,or E10,reading this thread brought back the same thing I encountered, a leak at what I thought was the "low fuel" sensor, it turned out that the tank had de-formed ,by the fuel pump penetration as a result of the use of E10, some have repaired this by "milling" the tank bottom penetration flat once again and sealing it up again, one of the new solutions is the product "Startron enzyme additive" to stabilize the E10 , my situation was a warrenty issue and the tank was replaced, all bikes with a poly tank are affected, ie: Ducati, Aprilia, big problems with the E10 as well ,, deformation of the tanks, only solution is the manufacturers have to catch up with the problem in the US,and it's going to become worse with the govornment wanting to put more in with E85,, it stinks,, don't store your bike with this stuff in the tank unless you've added "Startron" to stabilize it, my solution was simple, it's called CAM-2 race fuel,, I have availability near me at the pump,, no E10 in it,,so really go to the "Startron" site and read up on the subject of this crummy gas known as E10 it's causing many headaches,, and it will "never" reside in my tank again,, this is not the last you will hear of this issue ,it's just begun,, how KTM will handle it remains to be seen,, the SD tank retail is $1200, and after warrenty is up it's up,,the other thing to watch for is ,, fuel filter degradation, a "white" chaulky stuff on them,, as well as clogged injectors or a change in fueling,, oh , and people that have invested in the carbon KTM hard parts tank are having problems as well, with them "splitting" seems, and not really repairable,, now thats expensive !!

[kopfjager]

Depending on what State you live in there are several stations that sell fuel without Ethanol.


www.pure-gas.org

[woodstock101]

Originally Posted by dsw

Hi,

I've sprung a leak in my gas tank - from where the gas level sensor is bolted to the inside of the tank. I've replaced the o-ring and even just got a new o-ring and sensor. All to no avail - gas tank still leaks like a sieve. Wondering if anyone else had run into this problem or had found a solution.

Thanks!

I had the exact same problem. The good news was the bike was still under warranty and the dealer replaced the tank free of charge. Now I put a fuel stabalizer in with every other tank of gas or so.

[fast4d]

my 2008 SDR's tank is warped to the point where I had to modify the way it's mounted in order to bolt to the frame. no leaks even after I r/r the fuel filter. it never sits for more than a month until recently.

if you can't find startron LUCAS OIL makes a fuel stabilizer for ethanol. Stabil just came out with one as well. my KTMs are no longer daily riders so I use the additives with every fillup.

[RC8Rachel]

I was fussing and cussing because I noticed the same leak as described by the OP today as I walked into my garage and smelled gas. So I gather the best way to fix is to get a gasket sealer that is rated for fuel and put stabalizer in your fuel?

[RC8Rachel]

So I started going down the road of getting this fixed, called the dealership in WV where it was sold, called the KTM place here, called KTM North America and left messages with all of them.....so far...nothing........was about to call my lawyer (hey pre paid legal rocks!) when I figured I would just fix it myself. Got a bunch of fuel resistant O rings and gasket maker from Autozone, removed the tank, replaced ring, spread on the gasket stuff....and voila fixed. Also added the fuel stabalizer as well. I fell much better not having fuel leaking out of the tank....go figure lol. I needed to drain all the fluids anyway so figured why not.