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  • Fuel pump gasket

    Hello everyone.
    i have been trying to work out all the issues on a 2008 fuel injected Roadstar that has sat too long without any action.
    I removed the fuel pump to clean out the tank and clean up the pump and in doing so my gasket basically fell apart.
    I tried to reuse it along with some gasket material and sealant from auto zone but it leaked. I ordered a new gasket and installed it today.
    I leaks from one of the nipples...
    This is one of those jobs that is practically impossible to test until you have put the bike back together. Has anyone had any experience with replacing the gasket and is there a trick or some words of wisdom you could share?
    Thanks

  • #2
    I have a 03 that I replaced the sending unit on and it leaked fuel after. I tightened the bolts and it still leaked. Removed tank and sending unit again, everything looked perfect so I reinstalled using the proper torque spec and all was fine. Did you torque the bolts on your or just tighten them? I have never in my life loosened a bolt to stop a leak until this happened to my bike. Whodathunkit.

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    • #3
      I just tightened the bolts in the star pattern as shown in the manual. I’ll be sure to torque properly next time for sure.

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      • #4
        2.9 foot pounds torque equates to 34-35 inch pounds (preferred method) on the sending unit’s bolts.

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        • #5
          Thanks daveto and Bikerron.
          I have always had a bad habit of over-tightening, stripping or breaking fasteners. I think this time I erred on the side of not tight enough.
          I took everything apart and put it all back together again, and this time I torqued it to spec.
          The gas had been dripping onto the left floorboard, so I laid a paper towel on the floorboard after parking it.
          It has been almost three hours and my paper towel is still clean and dry.
          Wow... Follow the instructions. Who knew?
          Thanks!

          Comment


          • #6
            Just wanted to say thanks.
            I am getting ready to install the sending unit in my tank. I am sure I wouldn't have torqued the fasteners to spec.. This post most likely saved me from an inevitable fuel leak which I know would have ended up all over my fresh paint job
            Love this site.
            Jike.

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