Low fuel level sensor - leaking

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Vicks, Sep 27, 2011.

  1. Vicks

    Vicks gets stuck in sand

    Joined:
    Oct 4, 2006
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    3,308
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    Abu Dhabi, UAE
    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 ?

    [​IMG]


    [​IMG]

    cheers
    #1
  2. DSM8

    DSM8 Where fun goes to die....

    Joined:
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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.:lol3
    #2
  3. geometrician

    geometrician let's keep going...

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

    Here ya go
    #3
  4. v8toilet

    v8toilet Nothing to see here.

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    Hylomar +1
    #4
  5. Vicks

    Vicks gets stuck in sand

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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.
    #5
  6. geometrician

    geometrician let's keep going...

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

    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
    #6
  7. Orangecicle

    Orangecicle On a "Quest"

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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.
    :kboom
    #7
  8. Vicks

    Vicks gets stuck in sand

    Joined:
    Oct 4, 2006
    Oddometer:
    3,308
    Location:
    Abu Dhabi, UAE

    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.:clap
    #8
  9. triplenickel

    triplenickel Long timer

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    Hylomar and make sure your tank is venting properly.
    #9