FUEL TANK LEAK TEST

CAUTION: Place a dry chemical (Class B) fire extinguisher near the area before performing a Fuel Tank Leak Check. Before removing the fuel tank for a suspected leak, make sure that the fuel pipes or the tubes are not leaking onto the tank. Once removed, make sure that the fuel is not leaking around the fuel sender O-ring. Failure to follow these precautions may result in personal injury.

1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Remove the fuel tank.
3. Plug the fuel feed hose, the fuel limiter vent valve hose, and the fuel tank vent valve hose on the fuel tank.
4. Plug the fuel filler neck opening.
5. Connect a piece of the hose to the breather hose nipple on the fuel tank and secure the hose with one clamp.
6. Submerge the fuel tank in water or apply a soapy solution to the outside of the tank.
7. Apply 7-15 kPa (1-2 psi) air pressure to the breather hose.
8. Air bubbles appearing from the fuel tank indicate a leak.
9. Replace the fuel tank if the tank is leaking.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Fuel Tank Leak Test

Use the Manual With the Right Hardware

When to See a Mechanic

Rather have a pro handle this?