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Perforated overfill pipe: magic trick to fix this ? #5337918 02/01/20 06:49 AM
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Superflan Offline OP
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Hi,

A good friend has an issue with his overflow (? don't know the correct name, but it's above the fuel cap seal so it's for rainwater around the filler opening) tube of the fuel tank on a 2007 Kawasaki Z750.

A few months ago, he noticed that the water won't go down in there, so he used some chemical sink declogger and a wire, and it was eventually sorted out.

Now, the tank is leaking through the tube, there's a mild spot of fuel on the ground coming from the rubber pipe attached to the tube.

Did someone here been there and fixed that ?

TIA,
Super


‘01 Peugeot Partner 1.9 D, 15W40 E7, 273000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), 5W40 A3/B4, 23000 Km
Backup ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 170000 Km
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5337937 02/01/20 07:22 AM
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Astro14 Offline
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He perforated the pipe with chemicals - ouch...he's ruined his tank.

So, to fix the leaks, because it goes through the tank, he needs to replace that pipe. Depending on how the tank is made - solder, braze or epoxy a new pipe in place, ensuring a perfect seal.

OR, what's likely the most simple, and most likely to work: buy a new tank.

Last edited by Astro14; 02/01/20 07:23 AM.

32 Packard 15W40
01 Volvo V70 T5 0W30 AMSOIL SS
02 Volvo V70 T5 0W30 Edge
02 Volvo V70 XC 0W40 Edge
05 MB S600 0W40 M1
16 Tundra 1794 5W30 Pennzoil Ultra
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Astro14] #5337940 02/01/20 07:31 AM
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Superflan Offline OP
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Originally Posted by Astro14
He perforated the pipe with chemicals - ouch...he's ruined his tank.

Yeah I think basically the chemical cleaning left the inner unprotected and prone to rust, and it finally perforated.


‘01 Peugeot Partner 1.9 D, 15W40 E7, 273000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), 5W40 A3/B4, 23000 Km
Backup ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 170000 Km
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5337944 02/01/20 07:37 AM
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Smoky14 Offline
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As long as the bottom tube is still intact, seal it or cap it, seal the top end and carry a sponge to mop the water inside the filler neck.
Use fuel proof sealant, and THINK before your next fix.
Smoky


99 Acura 2.3CL 5speed MT
12 Ford Fusion 2.5S 6speed MT
05 Suzuki Bandit 1200.
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Smoky14] #5337947 02/01/20 07:46 AM
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Superflan Offline OP
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Originally Posted by Smoky14
As long as the bottom tube is still intact, seal it or cap it, seal the top end and carry a sponge to mop the water inside the filler neck.

Using this kind of fuel cap to prevent the puddle of water going in the tank when opening the cap with the stock cap ?

This : [Linked Image from ae01.alicdn.com]
Stock : [Linked Image from probolt-france.com]

Last edited by Superflan; 02/01/20 07:49 AM.

‘01 Peugeot Partner 1.9 D, 15W40 E7, 273000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), 5W40 A3/B4, 23000 Km
Backup ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 170000 Km
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5337953 02/01/20 07:57 AM
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Superflan Offline OP
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couldn't some epoxy be poured into the tube and a coating of it could stay in place when drying ? adjusting the ratio of the 2 components


‘01 Peugeot Partner 1.9 D, 15W40 E7, 273000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), 5W40 A3/B4, 23000 Km
Backup ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 170000 Km
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5337957 02/01/20 08:08 AM
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MParr Offline
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First of all, he won’t know the extent of the damage until he removes the tank and gets the fill assembly and vent separated from the tank. Hopefully he hasn’t messed up the tank. If the tank is unharmed, he will need to replace the fill assembly and vent. If the tank is messed up too, he will have to replace everything and get the tank painted. Expensive lesson either way.


2019 VW Tiguan SE 2.0 TSI Now: Castrol Pro OE LL IV 0W20 & OE VW/Mann
2017 Ford Escape SE 2.0T Now: Kendall GT-1 Max 5W30 FS & NAPA Gold 1348
2014 F-150 4x4 Now: Unk & Motorcraft FL-500s
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338015 02/01/20 09:17 AM
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Kira Offline
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"...he noticed that the water won't go down in there"?

"The bottom of the tube"? "The rubber pipe attached to the tube"?

Here is where a drawing is worth its weight in gold.

Sounds like a "rain drain". They need to be cleaned routinely just like sunroof drains but nobody ever does.

Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338019 02/01/20 09:20 AM
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Linctex Offline
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You could possibly slide the proper diameter of very thin-walled brass tubing down in there and epoxy it into place
[Linked Image from micromark.com]


"The evidence demands a verdict".
(Re:VOA)"it's nearly impossible to actually know the particular additives that are in there at what concentrations."
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Kira] #5338020 02/01/20 09:21 AM
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Linctex Offline
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Originally Posted by Kira
".
Sounds like a "rain drain". They need to be cleaned routinely just like sunroof drains but nobody ever does.


It sounds like his corroded or rusted through.


"The evidence demands a verdict".
(Re:VOA)"it's nearly impossible to actually know the particular additives that are in there at what concentrations."
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Linctex] #5338027 02/01/20 09:29 AM
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Astro14 Offline
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Originally Posted by Linctex
Originally Posted by Kira
".
Sounds like a "rain drain". They need to be cleaned routinely just like sunroof drains but nobody ever does.


It sounds like his corroded or rusted through.



After he “cleaned” it with drain cleaner and a wire...chemical corrosion and physical damage caused by poor methodology...


32 Packard 15W40
01 Volvo V70 T5 0W30 AMSOIL SS
02 Volvo V70 T5 0W30 Edge
02 Volvo V70 XC 0W40 Edge
05 MB S600 0W40 M1
16 Tundra 1794 5W30 Pennzoil Ultra
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338086 02/01/20 10:54 AM
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jeff78 Offline
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Originally Posted by Superflan
Now, the tank is leaking through the tube, there's a mild spot of fuel on the ground coming from the rubber pipe attached to the tube.


Ideally, stick a borescope into the tank and see if you can spot the damage to the tube.

If there's only a small amount of fuel, then I'd guess the tube was probably pierced somewhere above where the fuel level is now, otherwise the leak would be constant. And if the damage is high up enough, your friend might be able to manage it by simply not filling the tank up past the damage point.

Otherwise, he's probably looking at tank replacement.

Last edited by jeff78; 02/01/20 11:09 AM.
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338110 02/01/20 11:19 AM
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2019 VW Tiguan SE 2.0 TSI Now: Castrol Pro OE LL IV 0W20 & OE VW/Mann
2017 Ford Escape SE 2.0T Now: Kendall GT-1 Max 5W30 FS & NAPA Gold 1348
2014 F-150 4x4 Now: Unk & Motorcraft FL-500s
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338251 02/01/20 02:41 PM
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Superflan Offline OP
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Thanks everybody for your inputs. Yes, it's the "rain drain" that seems perforated and let fuel escape. From the parts diagram:

[Linked Image]

So I understand it's not a standalone part. So either blocking it both ends and preventing liquids going under the top of the fuel cap assembly, or replace reservoir? No fluid epoxy way someone ever tried?

I learn something here: I never saw or heard those motorcycledrains being clogged, first time always come.


‘01 Peugeot Partner 1.9 D, 15W40 E7, 273000 Km, running on WVO
Wife's '19 Suzuki Vitara 1.0 Boosterjet (TGDI), 5W40 A3/B4, 23000 Km
Backup ‘01 Toyota RAV4 3-dr 2.0 VVTi, 5W40 A3/B4, 170000 Km
Re: Perforated overfill pipe: magic trick to fix this ? [Re: Superflan] #5338422 02/01/20 07:00 PM
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MParr Offline
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Maybe the best way to go is to call your local motorbike shops and see what they can do for you. The tank may have to be removed and go to the shop. There comes a time to turn things over to others.
Yes, any tube exposed to the elements can become clogged. Many times, mud daubers are the culprits.


2019 VW Tiguan SE 2.0 TSI Now: Castrol Pro OE LL IV 0W20 & OE VW/Mann
2017 Ford Escape SE 2.0T Now: Kendall GT-1 Max 5W30 FS & NAPA Gold 1348
2014 F-150 4x4 Now: Unk & Motorcraft FL-500s
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