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Overflow line from tank dumping gas *need help*

696 Views 5 Replies 3 Participants Last post by  Cody6
My gsxr600 k4 is leaking gas slowly everytime I park, it’s coming out of the bigger of the overflow lines, the ones that come out of the bottom of the tank, Any advice would be great. not sure if it’s related but the fuel gauge doesn’t work either. Not sure if u can see from the photo below but it’s comming from the thicker of the 2 lines, how I originally found the issue is neither of them were plugged in and is was leaking down the side of the engine case
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I think the larger line is an overflow/rain drain from the area around the gas cap. You can confirm that by locating the hole there, putting something like gas or water down it, and checking where it comes out. If it is, the tube in the tank is probably cracked or rusted through. Pressurize it and locate the leak point. Some epoxy might seal it.
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Would bad ventilation have any effect should I replace the rubber lines? They are pretty beat up and cut. And is trying to spray the 2 holes in the top of my fuel tank (the breather hole and the overflow hole I believe you see them when u open the gas cap)with condensed air? Or is that a bad idea?
I replaced those hoses on my K4. They ripped like yours, and new ones were cheap.

I think Bill has the right idea. If you look at the service manual, it shows a cutaway of the gas tank, and where those tubes go inside the tank. IIRC one is a breather, and one is the aforementioned overflow. They both have real thin metal pipes that run up inside the tank towards the gas cap.

Either they corroded through, or maybe did you ever drop anything inside the gas tank you had to fish out? Or clean out the tank by putting bolts in there with a rust removing agent? Both those things could have caused damage to those little pipes.

Might just need a new tank, repairing a tank is usually very cost and time consuming, find a used one.

Or, if it's infact the overflow line that is the leaking one for sure, you could just plug the outlet on the bottom of the tank, and not ever overfill the tank, or let rain dry out around the gas cap before opening it every time. If its the breather line though, you absolutely cannot plug that one up, it is required for the tank to work normally. If it's the former, it could still work, or would probably make a great track tank.

Hope this helps.
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Thanks definitely helps the only issue is it leaks so slow I have a cup under the bike that catches it, it doesn’t even fill up the bottom of the cup over night, u know how coke cans have the raised middle that’s what I mean gas hasn’t yet reached the middle. Just leaks drops, doesn’t just poor out and some times it won’t do it, but the bike is garage kept always we have multiple garages.
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