Gas leaking from fairing bolt?! - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 15 (permalink) Old 08-17-2008, 02:55 PM Thread Starter
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Gas leaking from fairing bolt?!

Let me start of by saying this is my first bike, and my total riding experience equals the vast sum of 14.1 miles. So yes, I'm a newb. My bike is an '89 250 and it's rough, but it's been teaching me to ride so I can't complain. So on with my question...

I decided it was time to remove the tank today to do some much needed bodywork to it and repair some rust that had been allowed to crop up by previous owners (tank was primered). To my surprise, when I removed the first screw on the side where the front fairing attaches to the tank, gas started pouring out the side. You've got to be kidding me... the screws don't go all the way through the tank, right? I helped remove the tank on my friend's GSX-R and I don't recall getting covered in gas. So am I in dire need of a new tank? I can take pics of this if needed.
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post #2 of 15 (permalink) Old 08-17-2008, 03:00 PM Thread Starter
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Oh, and excuse me for posting this in the 250R forum... I'm noticing that it's all related to the '08 and up 250.
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post #3 of 15 (permalink) Old 08-17-2008, 03:34 PM
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No worries. This is for all 250 models. It's just that the new ones sold well. I honestly have no idea why you would be leaking gas, sorry I can't help. You're in the right place, though.

Bump.

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post #4 of 15 (permalink) Old 08-17-2008, 03:43 PM
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you should get a couple of pics up. It is really unusual (I can't even think of where any screw would be near the fuel!!). What was the screw holding (which fairing/part), and what was it screwing in to (frame/tank/bracket)?

congrats on your bike tho, and wanting to better it too. and welcome

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post #5 of 15 (permalink) Old 08-17-2008, 03:49 PM
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Or buy a used gas tank from ebay, craigslist, or kawiforums?

The national budget must be balanced; the arrogance of the authorities must be moderated and controlled... If the nation doesn't want to go bankrupt, people must again learn to work, instead of living on public assistance. Marcus Tullius Cicero, 55 BC

Dependence leads to subservience. Jefferson
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post #6 of 15 (permalink) Old 08-17-2008, 04:02 PM Thread Starter
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I appreciate all the posts. With so many '08 threads I figured it was limited to the newer Ninjas. I'll get some pics up here shortly. I did manage to find an answer when I searched in other sections. Turns out that a previous owner overtightened the screw, which causes it to penetrate the tank. It's partially a flaw in design, and partially owner incompetence. It could also be an aftermarket screw that was too long for the hole. I could try pushing some JBweld down into the hole and then threading the screw back in to seal it up, but with the shape that this tank is in, I'd rather just replace the whole thing. So I'll probably hit up some parts yards this week and see what I can find for the bike. It's too bad there's not a Pull-a-Part for bikes - that place has come through for me so many times with the cars!
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post #7 of 15 (permalink) Old 08-17-2008, 04:29 PM Thread Starter
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The bike:



The bolt in question:



As you can see, that tank has seen its share of trouble and probably isn't worth repairing.

Plans for the bike so far:

- New front upper and lower fairing
- Factory turn signals, no more deathwish flush mounts
- New mirror
- minor repairs to other plastics
- New windscreen
- New taillight
- PAINT!
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post #8 of 15 (permalink) Old 08-18-2008, 04:18 PM
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I think I know after reading your last post...Read the first warning near the bottom...click on the link below...Hope this helps!

http://faq.ninja250.org/wiki/How_do_I_remove_the_fairing%2C_fuel_tank%2C_etc%3F
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post #9 of 15 (permalink) Old 08-18-2008, 04:51 PM Thread Starter
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I've read a lot of stuff off of that site. Really good info. Hadn't seen that one yet though. Thanks a bunch for the link. I wish the previous owner would have read it, might've saved me from having to replace a tank. I might still try to salvage it though, after seeing how beat up most of the tanks for sale are this one isn't looking half bad anymore.

And add a whole new set of bolts for the plastic to my list up there. Anyone know where to get a good deal on those?
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post #10 of 15 (permalink) Old 08-27-2008, 01:43 PM
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So this just happened to my bike ('92 250) and I'm wondering what was done to fix. Did you end up getting a new gas tank? Or could this be JB welded or something? Just got my motorcycle license this week and was replacing broken fairings when started leaking gas. Boo!
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