03 Stone internal fuel pump tank in place of 03 EVT external fuel pump tank???

[chaoselephant23]

I had plans of fixing the gas leak on my 03 EVT today, but the tank had other ideas. Instead of a fuel level sensor leak as I had suspected, there is a pin hole leak in the crimped edge close to the fuel level sensor bung. This spot appears to have been welded before, but left to rot without any paint. This looks like it could be brazed easy enough, but I don't trust myself to perform the job without blowing the tank apart. I'll find a competent welder that is experienced in this sort of thing. But that leaves the bike down with little time left in New Englands riding season, which I would like to finish out until the snow hits the ground.

I do happen to have a tank from an 03 Stone with an internal fuel pump that's not being used as the Stone had flywheel crankshaft separation issues.

• Would it be feasible to use the internal fuel pump tank in place of the external fuel pump tank?
• Do you think the electronic petcock plug could be used to power the internal fuel pump?
• or would I need to run a self made Molex harness to the external fuel pump connectors? (have the connector as i will be trashing the fuel level sensor from the external tank as the gas made the wire sheathing brittle, it cracked and the copper is now exposed to air. won't be long before resistance builds up and boof)

Here are to do's of going this route:

• Disconnect external fuel pump so it does not burn out or spew leftover gas in the lines over the engine
• Take piece of hose and connect two nipples on the external fuel filter under the tank
• Plug up 12mm hose to external fuel pump so that it doesn't spew gas over hot engine parts

[Kiwi_Roy]

If the tank fits, why not?

Don't power the pump from the petcock wires, they are alive at a different time, the pump is powered from the relay along with the ignition coils.

Take the pump, filter and the pressure regulator off along with the return line, I believe the internal pump already has these, you must have the hoses that came with the tank.


Have you considered sealing the leaky tank with one of the tank liner products?

[chaoselephant23]

I had thought about it. Inspected inside the tank. Appears that Kream has already been applied at one time.

Looks like I spoke too soon as well. I setup the EVT tank on a test bench to determine where the leak emanated from. Wiped all surfaces down. Let the tank sit with 2 gallons of gas distributed more so on the side with suspected leaks for 4 hours while doing honey dos and entertaining random house guests. Blew some baby powder onto suspected areas. Baby powder showed the leak to truly be from the fuel level sensor  Leaking past both wires. Going to replace sensor, clean petcock screen, clean moat drain, mechanically clean rust off unpainted surfaces, repaint, and go ride.

Ill keep an eye out on the area of the tank I suspected. Get it welded up over the winter to keep one less thing on my mind during next years riding season.