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Old 09-27-2011, 11:59 PM   #1
Vicks OP
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Low fuel level sensor - leaking

Hey guys,

After i did a refresh of my '07 990S at 25,000kms i have a leaking fuel level sensor. The sensor seems to be pressed into the body which has the mounting holes. I had only taken it out while heat shielding my tanks. Now after i fitted it back with the O-ring in place, loctited and properly torqued the screws, it starts weeping once i fill it with gas. Initially the leak was bad, like dripping and then i removed it and coated the sensor mount body with some PVC pipe adhesive from the inside (which does not mix with petrol - i have tested this adequately) and the leak reduced to a weep, but it still is there. Any solutions other than replacing the damn sensor ?






cheers
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Old 09-28-2011, 01:50 PM   #2
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The is a permanent solution but cheaper than a new unit.

Epoxy in the sensor from the back.

Just make sure to prep the surface really well, sand it to give some tooth for the epoxy.

Just a KLR solution to a KTM problem.
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Old 09-28-2011, 04:30 PM   #3
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Hylomar

You want some Hylomar, you do... best stuff in the world, water, oil, gasoline, solvent, coolant resistant, non-hardening...

Here ya go
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Old 09-28-2011, 06:30 PM   #4
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Hylomar +1
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Old 09-29-2011, 02:11 AM   #5
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I tested some Metal epoxy and it holds up well immersed in petrol. The Hylomar seems to be good but I seriously doubt if I’ll find it here, but I’ll go look for it. Somehow I have a feeling I’ll end up with the metal epoxy. Thanks for the “rough up the surface” hint.
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Old 09-29-2011, 10:50 AM   #6
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Thumb Be Prepared

I carry Hylomar in my tool kit as well as steel epoxy

order some up for next time, could be another rider you'll save some day with it, I know I got a lot of miles out of a tube and fixed a lot of things trail-side
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Old 08-12-2013, 08:42 AM   #7
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I was wondering why my 950 smelled of gas when parked. Now I know. I have the same leak. New sensor ordered. It seems more safe than the alternative.
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Old 08-12-2013, 11:40 AM   #8
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Quote:
Originally Posted by Orangecicle View Post
I was wondering why my 950 smelled of gas when parked. Now I know. I have the same leak. New sensor ordered. It seems more safe than the alternative.

I roughened the surface before applying metal epoxy and 10k+ kms later, it is still good. So, don't discount a KLR solution to a KTM problem.
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Old 08-12-2013, 04:12 PM   #9
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Hylomar and make sure your tank is venting properly.
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