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Removed gas tank and fuel continues to flow out

3K views 8 replies 5 participants last post by  vstrommex 
#1 ·
I have a 2003 DL1000. I've recently started having running problems (rough idle, hesitation on throttle, popping/hiccups/backfire(or afterfire) type noises, stalling). On the drive to work, it was fine. On the ride home, it started having these problems. I was able to get home but it did stall a few times while I was riding it. At home now a few days later, when I start the motorcycle, it will run for maybe 5 to 15 seconds but with a very rough idle and then die. If I give it any throttle/gas, it dies instantly. When it was running fine, it usually idles around 1200-1400 rpm. I am thinking that maybe one or both the throttle body boots came off or became unseated. Also I'll look for any other disconnected hose or anything else out of place under the gas tank.

When I went to remove the gas tank, when I disconnected the fuel line, fuel continued to flow out of it. I expected some small amount to come out, but not to continuously flow from the tank like it did. I moved the tank over an oil pan to catch the flow and to see if it would stop. It didn't so I tipped the fuel tank up so it wouldn't come out.

My question is, reading on other posts about gas tank removal, only a small amount of gas is suppose to come out. What did I do wrong to cause it to continuously flow out? Maybe that is causing some or all of my problems?

Thank you!
 
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#4 ·
Yes the bike has the fuel filter bypass. I did replace that fuel filter since it is so easy to do now.

Fuel should not flow unless the pump is running. If it is, it may be involved in your problem. I've not heard of a bypass causing such an event either. The only thing that gets bypassed is the internal filter and that does not stop flow in a working pump. Something else is wrong.
Would the next step be to pull the fuel pump to see if anything is wrong with that? What would I look for or test?


Thanks again for the help!
 
#3 ·
Fuel should not flow unless the pump is running. If it is, it may be involved in your problem. I've not heard of a bypass causing such an event either. The only thing that gets bypassed is the internal filter and that does not stop flow in a working pump. Something else is wrong.
 
#5 ·
#6 ·
Here is the best I can find about gas running out of the tank when the bike is off and the fuel line is removed. It was in the External Fuel Filter modification page on VSRI.

Tombstone on 04/30/11 0612 Hours
I have the same result. The fuel running out. I filled a gallon bottle today before I plugged the hose. While it was running I would turn the key on and the pump would accelerate the fuel flow until it shut off. The bike has not started since I did the mod. I've re-taken the pump apart and can see no difference from the pics here..... Wall


Tombstone - did you find a fix yet? Sounds a lot like what happened to mine with the white plastic bit becoming unseated. When that happens the pump can't pressurize the gas. It will gravity-feed but of course not enough pressure for the injectors. I would double check the big fat o-ring where the plastic clip plugs into the pump body.
Trevor


Maybe something is not seated correctly or the o-ring is damaged. Now it's time to drain the tank.
 
#7 ·
Just to follow up on the fuel flowing from the tank when the fuel line was removed. I drained the tank and removed the fuel pump. The white clip on the fuel pump was loose/coming off and the o-ring it holds in was not seated correctly. I put it back together and reinstalled and now the fuel no longer flows out.

Also, a throttle body was misaligned and coming off. Once I reattached and tightened it down, the bike runs great again.

Thanks for the help!
 
#9 ·
Fuel flowing out if disconnected

I just replaced the mesh in the fuel pump on my 2008 DL 1000 and after I installed the fuel pump the same happened to me, the fuel did not stop flowing out if the hose is disconnected.

What I noticed is that the new mesh did not fit properly (I got on ebay), probably that is the reason. I will remove the pump it to check it and will let you know what I found.
 
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