Thursday, August 27, 2009

Fuel filter and filler neck gasket

Mileage: 9247
I was worried that my tank might have debris in it so I decided to change the fuel filter. I pulled the fuel cap and inlet neck off and looked inside. Much to my dismay I saw a great deal of rust inside. This is quite common of Ducs of this vintage, I cleaned out all of the rust and it is clear that I must seal the inside of the tank. There is a company called POR-15 that sells a kit for just this very problem. I will do it as soon as I get the materials from the company.

Another common problem is that the gasket under the fuel inlet rots out. Mine of course was bad so I swapped it out. This is not as easy as it looks! The gasket needs to be stretched just right to make a nice seal. After a few tries I came up with a technique of getting the inlet almost all the way seated and then putting the gasket on from the top. It looks great but I will be taking it out again soon to do the tank sealing.

Didn't ride, just cranked her up to be sure she runs.

Inserting the fuel pump with a new filter. Ugh, rust...

New fuel inlet gasket - not as easy at it looks.


Blogger Nick said...

Hi, Ive been struggling for ages trying to get the fuel filler gasket on without damaging the tank. You hint helped loads. Thanks

June 13, 2010 at 9:04 AM  

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