VN700 fuel system problems

[storm16]

I have been having an ongoing problem with my VN700 and fuel leaks.

When I bought the bike (an '85, the only year they made the VN700), it had a leaking fuel tank. I identified (or thought I had) the leak, it was between the mounting flange under the seat and the base of the tank itself. I filled it with JBWeld and thought the problem was fixed. Well, it was also leaking around the front left mounting flange. At this point, I got POR15 and sealed the inside of the tank. Problem solved, or so I thought again.

Well, I remounted the tank, and came home a day later to a garage full of gas smell, and the left side of the engine was damp with gasoline. I got my hands on a Clymer manual, and noted that the two petcock screws were supposed to have nylon washers on the screws. The manual says something to the effect of "do not attempt to use metal washers, they do not seal, and cause gas leaks." The previous owner did not have them on there, and I didn't know. I went looking for nylon washers, but could not find them at the Kawasaki shop, hardware stores, auto parts stores, etc. I did have some rubberized fiber gasket material, so I fashioned washers from that. I also replaced the petcock gasket (which the Kawi dealer did have in stock).

I reassembled the tank and petcock and left it on a tarp for 2 days. No leaks.
Another two days sitting on the bike. No leaks.
Last night, I bolted the tank back down and reconnected the fuel lines, and all of a sudden I'm smelling gas again.

Does this sound like a problem with the petcock? Could bolting it down to the frame be torquing the tank in such a way as to cause the leak? (When bolting it down, I did notice that the front flanges were bending slightly inward as I tightened the bolts. I thought this was normal.

Can someone suggest something? The tank is great until I bolt it down...And my wife has given me two unpalatable options...Store the bike outside or drain the fuel.

Also, does anyone know someone in Northern/Central Virginia who is good with Vulcans? I am going to need a carb job since I have not ridden the bike that much since I bought it (in June).

Thanks,
--Storm

[darkwolf29a]

There should be rubber gaskets that go around the bolts to hold down the tank. If those are shot, you may have a leak. My Clymer's says to make sure that they are in working order. You might just be tweaking the tank enough to cause the leak.

[herk]

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[elr658]

A VN700 is a V Twin (Think Vulcan 750) I beat the HECK out of one for a summer and 10K miles. I couldn't break it.


A ZN700 is a transverse four disco bike. A close descendant to the KZ650.

[herk]

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