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Old 01-07-2014, 10:30 AM   #16
Mikef5000 OP
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Joined: Apr 2008
Location: Columbus, OH
Oddometer: 2,030
Sorry for the delay, but the new Permatex 2 seemed to have done the trick. The pump appears to be sealed well, and I will forever use this stuff when doing fuel pump service (which hopefully isn't often).
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Old 05-15-2014, 10:38 AM   #17
Mikef5000 OP
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5 months (and several thousand miles) later, My fuel pump is leaking again. Just enough to be noticeable on the skid plate... no drips on the garage floor yet.

Disappointing.

I just wanted to update this thread if others are in my same predicament. Using non-hardening gasket sealer is a good temporary solution, but doesn't appear to be a long term fix.
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Old 05-15-2014, 11:56 AM   #18
pdxmotorhead
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Location: Portland OR
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If its any consolation, this problem is not unique to a KTM or even bikes, cars, trucks etc with in tank pumps and plastic fuel tanks have all kinds of issues with the flanges leaking where they bolt to the tank. I just replaced my 94 jeep wranglers fuel tank gasket for the 4th time in 200K miles.. And they are like 35 bucks each.. The plastic tank on the jeep has swelling and distortion issues too .
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Old 05-16-2014, 12:44 AM   #19
gefr
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Maybe a slightly thicker oring

It could be the closest to the OEM oring size (ID=60mm, t=3mm) but slightly thicker in inches. Even without boring the hole.
Cheers.
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Old 06-24-2014, 09:20 PM   #20
sparwood_rider
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Location: Kootenays, BC
Oddometer: 9
Pissed My trials and tribulations with the *ing o-rings

I wish I knew the root cause of this. Observations:

- The tank hole looks warped when you look inside, but the hole's diameter is constant where the o-ring seals.
- The flange surface on the tank is definitely not flat. When you disconnect the bolts, you can feel the tank flex. There's no doubt in my mind about this.
- The inboard front bolt always seems to be wet.
- Fuel comes out from under the flange on the front edge. The flange edge that faces the front of the bike.

Trying to band aid without truly knowing the root cause...

I've tried several of the 932's without success. I'm getting tired of pulling the tank on and off and staring at the ground under my bike looking for pools of fuel. I've tried both 75 durometer and 90 durometer. The diameter of the 932 o-rings were around 2.70 to 2.77 mm. I tried Seal All. It didn't seal sweet all even though I cleaned everything will alcohol and let it evaporate and take my time. I waited for it to get tacky… no luck. I'm currently testing the Dow Corning 55 o-ring sealant. I was able to swell the 75 durometer o-ring to 2.99 mm and then I put it back together. You can buy small containers of Dow 55 for $3 on-line. My local store wanted $80 for a toothpaste size container! I put the Dow 55 on the flange o-ring as well. It went into the tank relatively easy compared to the other trials. I put an excessive amount on both the o-rings. At this point I'm willing to try anything. I just put this on tonight. I also put "T Tape" a thread sealant used for natural gas and gasoline on the bolts. I put a lot of it on. The inboard front bolt is suspect as it always seems to be wet.

If this doesn't work, my next trials will be with Permatex form-a-gasket 1 and 2. I'll try the 2 first.

Hopefully something works. This is more of a vent than anything else. I'll give an update to let people know if the Dow 55 or T Tape did anything positive.

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Old 06-24-2014, 09:36 PM   #21
gefr
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I suggest trying a slightly thicker oring.

Thicker than 3.0mm. Also apply some vaseline when inserting. Seems you are really close.
Cheers.
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Old 06-25-2014, 10:34 PM   #22
sparwood_rider
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Question So far so good

24 hrs and no drips which is more promising than anything else I've tried.

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Old 06-26-2014, 08:18 AM   #23
AlxT
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I recently changed the filters and used a handful of Silicon - base lubricant (that stated on the label that it doesn't react with gas or petrol) on the oring as well as the tank itself and pressed the pump evenly on two of its corners until it popped in. Also after it pops in there was a minimal play so I moved it just a tiny bit in out so that the oring sits right. BTW, didn't even have to use the new rings, the old ones were in perfect shape.

Tapatalked @ sgsIV
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Old 08-06-2014, 12:01 PM   #24
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Eh? Still leaks

The 932 o-rings started leaking after 2 weeks. This was 2 days before starting out to ride the continental divide. I resorted to the Permatex 2 as mentioned above with the 932 (3mm dia) o-ring. I let it cure for 24 hours and then I smothered it like icing on a cake near the bolts and flange area. It lasted good enough for the 11 day 8000 km trip. It started leaking half way through the trip. The bike is currently parked outside because of the fuel leak. Will try the Permatex 2 again, but with a longer cure. I overfilled the tank many times which probably didn't help the Permatex since it was attacking it from the inside and outside.

What other products would anyone recommend for sealing the flange?
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Old 08-06-2014, 02:48 PM   #25
Margrave
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Had the same problem last year with fuel dripping from the fuel pump front securing screw (at 48k and 6 years). My tank had also distorted, with the hole measured oval by .024" and the tank mounting bolts increasingly difficult to align.
I tried new and larger o rings, DowCorning 55 seal lube and RTV under the flange - none of which fixed the leak for more than a week.
I then obtained some aerospace high strengh fuel tank sealer, applied both over and under the annular and flange o rings and reinstalled the pump - being careful not to over-tighted the bolts. This fixed it.
This 2 part mix sealant is manufactured by PRC-Desoto spec PR1770B (http://www.ppg.com/coatings/aerospac...70_class_b.pdf).
Managed to source some on fleabay.
It cures to a very tough rubber consistancy and does allow (with care) subsequent removal of the pump.
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Old 08-06-2014, 10:00 PM   #26
sparwood_rider
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Thumb Thanks for tip

I'll see where I can source this product. It sounds more promising than what I've tried so far.
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Old 08-07-2014, 04:53 AM   #27
rossguzzi
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How common is this leaking problem.

Has anyone changed out a pump and not had a leak?

Wondering if I should buy things to prepare for the worst.
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Old 08-07-2014, 07:58 AM   #28
orangepeeler
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Location: Flatlands of Colorado
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08-990 gas leak

On mine I found it was one of the threaded holes in tank was cracked. I used longer bolts and permatex #2 on threads and flange. Still dry after a year and several thousand miles..
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Old 08-07-2014, 06:03 PM   #29
sparwood_rider
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Question Bolt length

Any idea how much longer the bolts you used were?
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Old 08-11-2014, 06:14 AM   #30
orangepeeler
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Bolt length

Maybe 3/16" or less dont remember for sure. One bolt was partially stripped also and I bought bike new?
I thought mine was orings too til discovered cracked messed up bolt hole in tank.

Just came home from going thru your part of the world..beautiful country!!
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