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How Many Warriors Have Sprung a Fuel Leak?

69506 Views 289 Replies 124 Participants Last post by  Heftysmurf
Updated April 4th 2014:

It seems another large number of fuel leaks have occurred since the last update in September 2012. I expect we should be wondering why Yamaha has not done a recall to cover the 2002 left side dry-break, and also the fuel tank outlet Filter Assembly for the slipping-nipple that could spell disaster for any of us. I'm not wanting to be a 'mixer' I only want to document what's happening so we can continue to point Yamaha and it's dealers here when appropriate and when beneficial to safety.

Many members continue to point members here to this thread when we see they've posted about a fuel leak hoping that eventually there will be adequate data for Yamaha to perk-up and pay attention. We might be getting there. So if you have NOT yet reported a fuel leak on your Warrior here in this thread, please chime-in with the details and particulars, and especially please include your bike's model year. Its important we avoid duplicate reports so please check all the posts to be sure you have not reported prior. Then see Post#2 (below) for the places Warrior owners have reported fuel leaks.

This update includes Item# and Part# so we can visualize and locate the subject part much easier using either the Parts Manuals or using the Star Motorcycles disassembled views available on Yamaha/Star MC's website and also on many Yamaha/Star Dealer websites. All these parts are in the 'Fuel Tank' disassembled view.

More Place to Communicate:

[added} Plus this: http://www.rswarrior.com/forums/12-...3-warrior-fuel-pump-assembly-buyers-tips.html

[added} Plus this: http://www.rswarrior.com/forums/12-general-discussion/175095-main-fuel-tank-trouble-indicator.html

[added:} Plus this: http://www.rswarrior.com/forums/13-...fuel-leak-if-you-own-warrior-please-read.html
.

Attachment added 23July2016 because some images have disappeared over the years. Image by member 3youngns.

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had a leak on the mine. the elbow off the fuel tank separated. Luckily i was able to find an OEM replacement from local dealer. No other issues yet.
Seems like enough have popped off at the elbow that there should be a recall. It's dangerous as ****. Matt Seaworth had his burn down from that se elbow leaking. Had it happen on my.old Warrior, but I was only a couple blocks in so the motor wasn't hot yet.
Seems like enough have popped off at the elbow that there should be a recall. It's dangerous as ****. Matt Seaworth had his burn down from that se elbow leaking. Had it happen on my.old Warrior, but I was only a couple blocks in so the motor wasn't hot yet.
I only noticed the smell of fuel when parked in the garage, then noticed the slowly expanding puddle under the bike. It really seemed like the sleeve that the fuel line mounts to, just came loose. I don't know if those are friction fit, or suppose to be welded etc. but given what seems to be the quantity of issues, and the potential impact the defect causes, it should be a considered a serious issue.
'03 Warrior, just found out that my holding plate on the tank is leaking :mad:
Sorry, I need 10 posts to see the pictures here , so this is the last one, promise :p
I just developed a leak on the left side. Still haven't determined exactly where yet. Looked up in there but didn't see the source.

Is there a method for finding leaks other than flashlight/headlight and or taking it apart
Nope. If you read through this entire thread you will see examples of places it might leak, so you can look in the right places. Some disassembly required.

If its a small drip-leak then maybe you can ride until the top tank is really low or empty and the fuel light comes on, but if you suspect the leak is front-left-under the tank where the fuel line exits be careful. Other than that spot, its less worry about gas pouring out.
Great, just Great, what else can go wrong ?
Long-time lurker, first time poster (really thought I had posted before, but my emails showed nothing, so oh well). Bought my '02 Warrior in... I wanna say 2016 with the left dry-break leaking. Had 9k miles. So had that replaced right off. Now it's got 28k miles and noticed another gas leak. I could be crazy, but it appeared to be just leaking from the right side (high side when on the stand) fuel line. The dry-break under the seat looked fine and the other line that snaps in with the fitting looked fine too. It seemed the metal clamps on the ends of the lines were failing. Is that possible?
Attached pic shows in red where I believe the leak was coming from (line detached now, clearly), and blue shows where it was pooling (low side when on stand).
249495
Auto part Fuel line Automotive fuel system Fuel pump Carburetor
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Well I had something weird happen about 2 weeks ago, went for a decent long ride, had to fill up about 20 miles before i got home. When i got home i could smell gas and I assumed I overfilled and it was coming through the overflow line on the tank. a week laer could still smell gas, I had to do some work on the bike and had to get the tank off and there was some fuel by the left side Drybreak so i assumed it wasn't clicked in properly.

I had the tank off the bile for a couple of days and no leak on the tank side Drybreak. I know because i checked the lines and the break. Well when we put the tank back on the bike as soon as the we connected both ends of the left side drybreak the part of the break going to the sub tank started going damp with fuel i could not see any visible cracks. Luckily had an old spare sitting in a bunch of parts I gotten sometime back and just replaced the end goin to the subtank and all seems good so far no leak no gas smell. I just thought it was odd the drybreak failed in the middle of a ride.
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Yours is a 2002 model year. The left side dry break is known to crack on the side facing the bike. Pics are in this 'sprung a fuel leak' thread. This entire thread is good to study.
Is this the leaky "elbow" everyone is talking about? If so, does the elbow get replace on its own, or do I replace the whole upper plastic plate. Part number(s)?

Thanks!

Long-time lurker, first time poster (really thought I had posted before, but my emails showed nothing, so oh well). Bought my '02 Warrior in... I wanna say 2016 with the left dry-break leaking. Had 9k miles. So had that replaced right off. Now it's got 28k miles and noticed another gas leak. I could be crazy, but it appeared to be just leaking from the right side (high side when on the stand) fuel line. The dry-break under the seat looked fine and the other line that snaps in with the fitting looked fine too. It seemed the metal clamps on the ends of the lines were failing. Is that possible?
Attached pic shows in red where I believe the leak was coming from (line detached now, clearly), and blue shows where it was pooling (low side when on stand).
View attachment 249495 View attachment 249495
Okay, I see this is NOT the elbow others are referring to... though it is also clearly an elbow. That's the "FUEL PUMP COMP. Part # 5PX-13907-00-00" found here at #91 (last) on the list: 2007 Yamaha Road Star Warrior XV17PCW FUEL TANK Parts - Best OEM FUEL TANK Parts Diagram for 2007 Road Star Warrior XV17PCW Motorcycles
Appears to be all one part... and one I'm not trying to replace if I can get away with it. Any sealing advice? That Permatex gasket seal someone mentioned earlier? Anything better?
Thanks!
That is the plastic elbow correct? JB Weld should work
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Do a forum search for fuel+pump and review for posted pics showing damage and repair, then compare to your damage for repair examples.
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Well looks like I have a fuel leak somewhere. I read in the thread there was a recall so going to search for that's and see if I have it done.

07 14k miles
Not sure exactly where it is leaking yet. Need to pull the tank.
250246
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Well looks like I have a fuel leak somewhere. I read in the thread there was a recall so going to search for that's and see if I have it done.

07 14k miles
Not sure exactly where it is leaking yet. Need to pull the tank. View attachment 250246
The nipple on the end of the fuel line pictured comes loose from the housing, judging by the fuel stain I'd bet this is your problem.

Sent from my SAMSUNG-SM-G930A using Tapatalk
That aluminum fitting that attaches to the tank uses a press-fit connector that is known to come loose. Check through this thread for pics by other members and you will find a match and will know where to look and what to do. I know its a long thread but its worth the time.
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