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  • Fuel Pump Gasket Question

    In my last thread, the kind and knowledgeable people on this site suggested that I might have a leaky fuel pump gasket. Although I'm not the most proficient wrench-turner, I managed to remove my gas tank and determine that I do indeed have this problematic gasket. At least I think I correctly diagnosed this- it's the seal around the gold colored "thing" attached on the underside of the gas tank (sorry to sound like such a moron).

    Before I did this, I called my local Suzuki dealership who told me that my bike already underwent the recall for this problem in 1998 (I'm not so sure about this, but I can't really argue with the service guy and his computer records). So now I need to order the part and replace it myself (I can't really afford to take it to the shop, and I'm pretty confident that I can do a good job myself with advice).

    I want to make sure that I do this repair correctly, so I'd like to enlist the help of TLplanet members again: Can someone verify which part listed in the ronayers.com diagram below is the one I need? I assume its part 12 (the gasket), but do I need part 11 too? Also, any suggestions on what type of gasket sealer would be best? Thanks in advance.

  • #2
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    • #3
      :dunno grab both?

      Clean the tank base up as best you can, use some fuel resistant RTV sealant too, don't over tighten the bolts, and do them up in a criss-cross fashion.
      "I spent most of my money on Scotch, women and cigarettes. The rest I just wasted"

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      • #4
        Thanks for the reply. I was thinking of grabbing both, but I just wanted to check to see if anyone has done this repair before and can tell me exactly what is needed to do the fix (I can't afford to buy any parts that I don't need).

        Also, a friend of mine (who has worked on CARS for about 15 years) told me NOT to use any type of sealant because none are really resistant to gas. Any opinions on that?

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        • #5
          Yep, I've seen fuel / oil resistant sealant. You probably will get away without using it, but I would, just so I didn't have to do it all again in a few weeks.

          I haven't had to do it, but it is not an uncommon problem.
          "I spent most of my money on Scotch, women and cigarettes. The rest I just wasted"

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          • #6
            I've done it. Permatex #2 is non hardening and gas resistant. I didn't even buy a new gasket and it worked great. It has lasted over a year now.

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            • #7
              Hrm, I must have gotten preferential treatment at the Suzuki dealer. After having had my tank replaced once already and 2+ years out of warranty, the shop replaced my fuel filter gasket FREE of charge (Of course I had purchased 3 bikes from this shop)
              -Randy

              Whoever said the best things in life are free, obviously never owned a motorcycle.

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              • #8
                I agree with NOT using a sealant of some kind.
                You really shouldn't need to. I know there are guys here who've done it with no problems but if the you use a new gasket, make sure the tank surface is clean/rust free etc and torque the pump correctly, it should be fine.
                I've had my pump out a few times over the years and never needed any kind of RTV etc.

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                • #9
                  BrUiRcNeR, do you mean fuel pump gasket, or fuel filter gasket? sounds like you've found a good dealership there.

                  Zero, thanks, I'll get the permatex #2.

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                  • #10
                    Wow, now I have two votes for sealant and two votes against sealant.

                    This is getting interesting!!

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                    • #11
                      Originally posted by raamses
                      BrUiRcNeR, do you mean fuel pump gasket, or fuel filter gasket? sounds like you've found a good dealership there.

                      Zero, thanks, I'll get the permatex #2.
                      OOps, I meant Fuel Pump Gasket.
                      -Randy

                      Whoever said the best things in life are free, obviously never owned a motorcycle.

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                      • #12
                        I agree with NOT using a sealant of some kind.
                        Ryno, I know you know your stuff, so what's the problem with the sealer. I have a 97 TLS vs. your TLR too. The 97's had problems with leaking, so while I had it apart I just put some sealer down and torqued the bolts. It was more of a time thing than a money thing. I didn't want to wait to order a gasket while it was apart, so I used the sealer. No problems since and it's under the tank, so it's not like you see it.

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                        • #13
                          I had a leaky fuel pump gasket after changing gas tanks. Repeated advice from a couple of shop mechanics and numerous people on a couple of TL boards said that this is very common regardless of recall. The manual is EXTREMELY specific in how to install the gasket. There is a very specific star pattern that must be followed and the torque required is like 2.5 ft lbs IIRC (please check the manual to confirm torque spec). This is so loose it almost seems like it can't be true, but find a quality torque wrench with *inch* pound adjustments and trust the designers. The advice that I got was to follow the manual EXACTLY and you won't have any problems. Sure enough I've run into a bunch of folks who "sort of" followed the procedure and still had problems. I followed them to a T and haven't leaked a drop in over a year. Just be sure that the tank surface is completely clean and free from and little nicks or residue from the old gasket.
                          Nathan
                          2001 Ducati 996
                          Former 1997 TLS Owner

                          Of all manifestations of power, that which most impresses is restraint - Thucydides

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                          • #14
                            Mine was leaking. I replaced the filter and did not use a sealant. It hasn't leaked.
                            I know nothing about bikes.

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                            • #15
                              I replaced the filter and did not use a sealant. It hasn't leaked.
                              Which filter did you replace that stopped the fuel pump from leaking?

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