Fuel Tank Leak Gen II...Check Yours

[RavFJR]

As I was finishing up on some maintenance I did on my bike (putting the bike back together), I noticed a gasoline smell, and then a leak at the left hex bolt that holds on the rear plastic tank skirt. It appears that a tank defect has allowed the hex bolt to rub against the tank and then penetrate it, causing a hole. This defect might just be specific to my bike, but I thought it important to share the info with the forum. I’m still working with Yamaha on this problem, so as of now, I’ve received no feedback from them. I would hate to think what could have happened if this leak started while riding…

 

[SkooterG]

Edited title since Gen I owners won't have to worry about this.

Scary.

 

[mcatrophy]

As I was finishing up on some maintenance I did on my bike (putting the bike back together), I noticed a gasoline smell, and then a leak at the left hex bolt that holds on the rear plastic tank skirt. It appears that a tank defect has allowed the hex bolt to rub against the tank and then penetrate it, causing a hole. This defect might just be specific to my bike, but I thought it important to share the info with the forum. I’m still working with Yamaha on this problem, so as of now, I’ve received no feedback from them. I would hate to think what could have happened if this leak started while riding…

Presumably you mean the upper one in this pic (click on image for larger view):



The threaded part on the tank should be flat:



Either the screw was too long or the tank wasn't shaped correctly. If the former, you might have trouble claiming against Yamaha, they will say someone put an incorrect screw in. Does the head of the screw look like the one in my pic?

 

[rushes]

Just measured my 08 and I have approximately 2mm clearance.

The screw measures 8mm of thread, the plastic skirt measures 3mm thick, and the depth of the indention in the tank is a little over 7mm. Same thing on the right side.

Maybe a longer screw found it's way there?

 

[RavFJR]

Yes, it is this part of the tank you are referring to ( I couldn't provide pictures, as Yamaha has the tank). And yes, the OEM hex bolt was installed.

Relating to your second picture ,my threaded plate is indented (has been since I owned the bike new). The problem appears to be (by the assessment of the dealer) either a manufacturing or assembly defect. There is no indication of anything striking this area of the tank.

 

[Fairlaner]

very weird.....

R

 

[mcatrophy]

Yes, it is this part of the tank you are referring to ( I couldn't provide pictures, as Yamaha has the tank). And yes, the OEM hex bolt was installed.
Relating to your second picture ,my threaded plate is indented (has been since I owned the bike new). The problem appears to be (by the assessment of the dealer) either a manufacturing or assembly defect. There is no indication of anything striking this area of the tank.

The threaded plate being indented will certainly allow the screw to move further towards the tank (bending the plastic skirt in the process), and so rub on it. I'm a little surprised it could penetrate the tank, the screw is quite soft, but proof of the pudding ...

It would be very difficult to accidentally bend that plate, it's normally protected by the seat, so does sound like a defect.

Very rare!

 

[RedPorscheKilla]

Thanks for the hint anyway. That's really scary though!! 2 mm ain't not enough meat to warrant a comforting feeling in that area....

V

RPK

 

[odot]

Hmmm.....so there is going to be a recall on all the spiders?

 

[RavFJR]

Yes, it is this part of the tank you are referring to ( I couldn't provide pictures, as Yamaha has the tank). And yes, the OEM hex bolt was installed.
Relating to your second picture ,my threaded plate is indented (has been since I owned the bike new). The problem appears to be (by the assessment of the dealer) either a manufacturing or assembly defect. There is no indication of anything striking this area of the tank.

The threaded plate being indented will certainly allow the screw to move further towards the tank (bending the plastic skirt in the process), and so rub on it. I'm a little surprised it could penetrate the tank, the screw is quite soft, but proof of the pudding ...

It would be very difficult to accidentally bend that plate, it's normally protected by the seat, so does sound like a defect.

Very rare!

I think me going over the the bike and re-tightening bolts, etc. was when it penetrated the tank. However, the almost four years of abrasion was the culprit that weakened the metal. I should have (a couple of years ago) realized that there was an issue, as I'd replaced the rear plastic skirt because it cracked while installing it... I will report what Yamaha shares with me, once they get back with me.

 

[escapefjrtist]

This is new...haven't seen anything remotely like that in all the GENIIs we've worked on.

Thanks for the heads up, definitely something to look for.

--G

 

[SkooterG]

POS Gen IIs.... When will you motherfuckers learn?

 

[PhilJet09]

Yes, it is this part of the tank you are referring to ( I couldn't provide pictures, as Yamaha has the tank). And yes, the OEM hex bolt was installed.
Relating to your second picture ,my threaded plate is indented (has been since I owned the bike new). The problem appears to be (by the assessment of the dealer) either a manufacturing or assembly defect. There is no indication of anything striking this area of the tank.

You keep referring to this fastener as a "hex bolt". The OEM part is a short, pan-head screw with a hex drive (Allen wrench). Makes me think you have the wrong fastener.

 

[RavFJR]

Yes, it is this part of the tank you are referring to ( I couldn't provide pictures, as Yamaha has the tank). And yes, the OEM hex bolt was installed.

Relating to your second picture ,my threaded plate is indented (has been since I owned the bike new). The problem appears to be (by the assessment of the dealer) either a manufacturing or assembly defect. There is no indication of anything striking this area of the tank.

You keep referring to this fastener as a "hex bolt". The OEM part is a short, pan-head screw with a hex drive (Allen wrench). Makes me think you have the wrong fastener.

Okay... A bad play on words from me - I hope I'm forgiven. I had the OEM pan-head screw with a hex drive (Allen wrench) installed when the leak occured.

 

[PhilJet09]

Yikes! That sucks, hope Yamaha will provide warranty relief for you.

 

[RavFJR]

Yikes! That sucks, hope Yamaha will provide warranty relief for you.

The warranty relief request is in the works and is being backed by the dealership's owner and Service Manager. I was told that Yamaha has a new 'Web Based' request process that takes a bit longer than the previous 'phone in' request.

 

[RavFJR]

UPDATE: Well, Yamaha has determined that this problem was a result of a manufacturing defect and is honoring warranty relief for a replacement tank. My only out of pocket expense will be an hour of labor to install the tank on the bike (due to liability reasons). Hopefully this defect was just something on my bike, and no one else will succumb to what I've experienced. I'm relieved (and happy) that Yamaha has stood behind their product - thanks Yamaha!

 

[PhilJet09]

Glad they did the right thing!

 

[mcatrophy]

UPDATE: Well, Yamaha has determined that this problem was a result of a manufacturing defect and is honoring warranty relief for a replacement tank. My only out of pocket expense will be an hour of labor to install the tank on the bike (due to liability reasons). Hopefully this defect was just something on my bike, and no one else will succumb to what I've experienced. I'm relieved (and happy) that Yamaha has stood behind their product - thanks Yamaha!

Good result, although I don't see why you should be charged for the labour. It wasn't your fault it was defective. If Yamaha insist on the dealer fitting it, IMHO they should pay.

Depends on whether you want to fight it.

The easy way is to accept things as they are and just ride.