Leaking Gas from Overflow Line.

[MitchC]

Hey guys!

I think it's literally been YEARS since I've been on the site. Sad thing is, what brings me back is I need your help.

I just picked up my 2003 SV650S from the dealership yesterday after getting a full service completed.

Noticed the bike was really low on gas, stopped to fill up, rode for about 15-20 kms with no issues, went home and parked the bike. After this, I went out for dinner around 5 PM, went to the movie, and came back home around 10:30 PM to this:



The leak is coming from the fuel overflow line. Normally, I would just assume I put too much gas in. But it is still dripping a day later.



I have since been able to clamp the line off, but feel I shouldn't be riding the bike this way. Obviously I will be kindly "talking" to the dealership tomorrow when they open.



I was just wondering if there is anything I might be able to do in the mean time?

Thanks for the help, it's great to be back!

Mitch

[jambo]

The curvy SV suffered from rust in the drain pipe that went through the tank from the hole in the filler neck, to the drain hose at the back of the tank. This happened if the hose or pipe got blocked leaving water in the steel pipe, which could then corrode, letting fuel from the tank straight out of the drain hose.

Hopefully this is not the case, as your best bet in that case is a replacement tank.

Jambo
Sent from my thingie

[MitchC]

Originally Posted by jambo

Hopefully this is not the case, as your best bet in that case is a replacement tank.

I do hope this isn't the case because after removing the filler cap where the metal hose lines; specifically the one of the left hand side of the bike, does look slightly corroded.







Mitch

[MitchC]

Hey,

Others have mentioned it might be the clamps that hold the fuel delivery pipe? I've attached more photos for clarification. I'm about to remove the airbox to see if I can get a better look at these clamps.





Mitch

[jambo]

What did you find?
I'm not sure how a leak from the pressurised system to the injectors would lead to fuel flowing out of the drain hose.

Follow the drain hose up and isolate the leak that way.

Jambo
Sent from my thingie

[Sid Squid]

Get a piece of hose with the end cut perfectly square, press it firmly against the hole in the filler well and blow, can you hear the air coming out inside the tank? If yes, then the tank inner piping is goosed.

[MitchC]

Hey,

It was exactly what I feared. They found out my tank overflow line has corroded, so a new tank is required! YAY!

So I am looking for a SV650S tank from 2003 in Sonic Silver in good condition.

Thanks!

Mitch

Being frugal, I think I'd just cap the drain line at the rear of the tank, then try to remember not to fill the tank too full.

[timwilky]

Isn't this dual purpose? to also act as a drain for any water.

If you block it at the base, best also block at the top. But, how do you then stop water getting into the tank when you take the filler off?

Yes of course you're right about it being a water drain too. Probably only a problem if you park outside in the rain? Perhaps cover it somehow under those conditions?
Wouldn't be the first time I created a problem with one of my frugal solutions!