OOOOPS!!

[JohnnyW]

Thought I'd get started on my first service of my new(to me) bike, 2001 gs1150, 51,000 miles. One of the items on my list was to change the fuel filter. All going well until I was undoing the second of the nuts securing the mounting plate for the filter/pump to the tank. It felt a little stiff but nothing too bad and then came the realisation that the stud had sheared What are my options, if any

JohnnyW

 

[Grizzly]

Oh Dear!

This has happened to quite a few before you Johnny - do a search. Quite a few have refitted the pump assembly with one nut/stud missing and had no problems
The large o-ring seems to go a bit "oversize" so when refitting, grease the o-ring thoroughly and sit as centrally as possible then tighten down the nuts equally/evenly and o-ring should "pop" into seat ok.
Also, copper-slip studs and nuts and smear with grease to protect.
If you try rebuilding with the stud missing, check carefully for any signs of a leak with the tank full to the brim.

Cheers.................Grizzly

 

[JohnnyW]

Thanks for that, Grizzly, I did wonder if it was possible to do without one stud. I'll clean up all the other studs' threads and coat them in copperslip, though I don't think I'll be rushing to do this job again. I've got a new O ring which should help with getting a good seal. Those clips on the fuel lines are a real pain!!

JohnnyW

 

[Grizzly]

Clips

I know what you mean about the clips I'm sure the last time I found you can just "ease" the hoses off without releasing the clips - just lever against the end of the hoses with long nose pliers until they "pop" over the bell-end on filter?

Hope all goes well.........................Grizzly

 

[Madmountainman]

Worst case scenario is a fuel tank replacement, but a good welder will be able to fit a new stud if it's required.

 

[MikeO]

Happened to me a while ago...

Mike

 

[Fanum]

While it's open, plan ahead so you are unlikely to have to open the tank up again soon......EG look at sticking the filter OUTSIDE the tanks so it's replaceable in 2 mins flat.

Then, look at it as a basic engineering problem.......you could go to the hassle of draining and making safe the tank for welding, or you could use a bead of non-silicone sealant (silicone fucks up lambda sensors) plus the O ring and see if you can establish a good seal (you WILL be able to, DAMHIK!) or you could drill a hole 10mm or so along from the busted stud, use a few assorted Stainless nuts, bolts and penny washers plus a bit of sealant and bolt it all up again nice and securely.

Many 11XXs are running around quite happily with a missing stud or two, many have been bodged in a good way.


If all else fails, look for someone who has a second hand tank in good nick