Leaking Fuel Lines Tighten and/or Replace?

[Sunbeemer]

Well it finally happened today, one of the rubber fuel lines started leaking (just seeping really) because the Oeticker clamps weren't tightened enough, so I tightened them all with a small pair of dull nippers (which look a lot like the Oeticker crimping pliers) and that stopped the leak. BTW, I've noticed the smell of gas when the temps dropped more than 20 degrees, but never could find the source of it before. Anyway, I remember there was a recall about this, so I called the local dealer service folks who told me it's really rare and hardly ever a problem. However I noticed that the inside layer of the rubber fuel lines have fine cracks apparent at the cut end. Think I should replace them? If so, with what type of hose? It says 8 X 13 BMW on these two short hoses between the quick-disconnects and the metal fuel-distributor lines.
It's an '02 with 16k miles.

[Boxer]

the local dealer service folks who told me it's really rare and hardly ever a problem.

That dealer has had his head in a hole the past three years.

[deptom]

Happened to me early this year. First start of the engine, fuel just started to leak coming from under the tank. Had it checked. Turns out the tip of the rubber hose had some cracks. Had to take a real closer look to notice. My friendly local dealer mech replaced it.

[Capt. Blackadder]

...so I called the local dealer service folks who told me it's really rare and hardly ever a problem.

Riiiight... both the crimp-style clamps and those stupid plastic quick-disconnects are a chronic and well-documented problem on these bikes. I am all too familiar with this problem myself, and finally gave up and installed solid lines from the tank to the fuel pressure regulator, scrapping the quick-disconnects. Problem-free ever since.

I did learn a little trick while my bike was suffering from these fuel leaks: Switch the bike on, let the fuel pump complete its pressurization of the fuel lines, then switch it off again. The leak will start, but stop soon because the fuel will swell the lines slightly. Five minutes later, it's ready to ride. No leaks.

If your tightening of the clamps stopped the leak, great... but I can almost guarantee you that it will start again. The only permanent solution is to replace the crimp clamps with proper screw-type clamps intended for pressurized fuel lines, and possibly also to replace the fuel lines if they've started to crack. Sorry, I don't have the fuel line part number(s) right now.

[NCPadgett]

It happened to mine a few weeks ago. Took it in to the dealer and 5 minutes later I am on my way leak free.

[Sunbeemer]

Thanks for your helpful replies. I'll remember to pre-wet the fuel lines by cycling the pump should (when?) they start leaking again. I think the gas is weeping through the small, longitudinal cracks in the inner liner of the hose and tightening the clamps has just delayed the inevitable. I bought some brass quick-disconnects at our local Goodyear Rubber store (which look like the ones from Omega, but use threaded hose barbs) to replace the stupid plastic ones, and will change both the hoses and clamps when I do that job.

[phastphil]

I just posted about the leak on my '02, but the dealer said there was a recall on the gas leak issue. Not sure how far back that applies. They fixed it under warranty.

However, I'm looking for a solution to the yellow stains the gas leak caused on the transmission case.

[jb44]

... so I called the local dealer service folks who told me it's really rare and hardly ever a problem.....

Sunbeemer,

Just curious... Tampa BMW or Haps?

jb

[Sunbeemer]

It was Tampa BMW JB44... And I'm going to contact them again to see if they'll replace the cracked fuel lines under the recall. If they balk at all, I'll do it myself (and install my brass disconnects while I'm at it).

[phastphil]

My dealer didn't say what they were going to do - other than take action as per the recall, but wondering if any of you guys have a 'friend' at a dealer that we could see the actual Recall notice and find out what it specially applied to.

Phil

[rdsmith3]

Here is the recall info:

Make : BMW Model : R SERIES Year : 2002
Manufacturer : BAYERISCHE MOTOREN WERKE
NHTSA CAMPAIGN ID Number : 04V028000 Recall Date : JAN 15, 2004
Component: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
Potential Number Of Units Affected : 39000
Summary:
ON CERTAIN MOTORCYCLES, THE O-RING IN FUEL LINE QUICK-DISCONNECT COUPLING COULD BECOME DAMAGED AND LEAD TO A FUEL LEAK. THERE IS ALSO A PROBLEM INVOLVING CRIMP-TYPE HOSE CLAMPS, WHICH CAN RESULT IN A FUEL LEAK.
Consequence:
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy:
DEALERS WILL INSPECT AND, IF NECESSARY, ADJUST ALL CRIMP-TYPE HOSE CLAMPS. ALSO, ALL FUEL LINE QUICK-DISCONNECT COUPLINGS WILL BE INSPECTED. IF A LEAK IS DETECTED, THE QUICK-DISCONNECT O-RING WILL BE REPLACED. IF DAMAGED, THE COUPLING WILL BE REPLACED. OWNER NOTIFICATION BEGAN ON APRIL 30, 2004. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.
Notes:
CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION’S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236

found here at NHTSA

http://www-odi.nhtsa.dot.gov/cars/probl ... ersion=YES

or try this

http://www-odi.nhtsa.dot.gov/cars/probl ... esults.cfm

[phastphil]

Duh, I guess I could of done that - I didn't even think they would list motorcycles - but thanks for the info.

I called BMW Motorrad today and filed a claim - they were not overly anxious to commit to a new transmission housing, but well see.

Phil

[Sunbeemer]

I called Tampa BMW again today to find out exactly what they do during this recall service, and was told that they only tighten the clamps with the special clamping tool (Oeticker pliers?) that allow them to be tightened to the correct spec and no more. He told me that overtightening the clamps is even worse than undertightening as it crimps the tubes the hoses attach to. Well, I don't know if it's worse than having gasoline running down onto your hot cylinder with 90mph wind blowing it up your pant leg or not, but it could be worse, it could ignite!

Oh, and they don't replace the cracked fuel lines under the recall, but will replace the quick-disconnects if they are leaking, which he said they usually only see on bikes that have been stored in hot areas, but not usually on ones that have been ridden often.

I'll do it myself.