Check to see if you pinched any wires under the flange .
If so, check to see if the top flange on the lower tank is still straight.
It is very thin metal and easy to distort the sealing surface .
If you can get it close to being straight, a layer of Pematex #3
can seal it up, but of course it would be more prudent to replace the lower tank.
Both sides were not straight to the touch, but it sealed previously, i.e. before I took it all part, and there was no evidence of sealer.
I also originally installed the gasket with the incorrect tightening process, guess that could have contributed to the seepage/leaking.
I'm going to replace the gasket again before replacing the tank. Several tanks for sale, price aren't too bad, and the manual makes it sound like a fairly painless process. (doesn't it always?)
As usual the manual is not quite 100% on what it takes to remove the lower tank.
Great
writeup on removing the lower tank, but I'm going to try the Permatex #3 route before replacing the tank this year, next winter yes, but now?
+1
This happened to me and just like you I didn't discover it until I was fueling the bike up at the pump. I simply lifted the top of the lower tank, saw what had happened and then put the pump back in the way it was meant to be. It has sealed fine ever since. The torque spec for those acorn nuts is not that high so don't go nuts when tightening them...
Unfortunately, that didn't work for me. Looks like I'll at the very least require a new gasket, and maybe a new lower tank.
Edit - You were right, it was one of the wires internal to the fuel pump assembly, also it was what deformed the lip of the tank. I managed to straighten the lip and poured in 2 gallons of fuel and...no leak. Only problem, it was 87 octane fuel for the lawnmower.
I also double hose clamped the hose, not tight, just enough to "squeeze". No leak at that location either.
Again, I appreciate all of the advice and assistance and it looks like the leak problem is fixed.
M.
