|  | Topic : $12 of gas on the ground - gas line failure |  |
| | | MotorMac | | Jupiter |  |  | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 28 Jun 2024 - 19:45 Post title : $12 of gas on the ground - gas line failure | | | Stopped for gas yesterday, hung up the nozzle and noticed a puddle on the ground. Near as I can tell, the "double check clip" connecting fuel line to tank came loose. Limped home spewing gas from under front of tank the whole way.
Last time I had tank off was July 25, 2023 when I replaced fuel pump, almost a year ago.
Anybody else ever have trouble with fuel line connector to tank? Everything else looks solid, connector pulled off way too easy, not the fight I expected - wondering If I forgot to lock it.
Connector doesn't appear in parts list that I can find, no part number, only marking on it is "STAR." No search results so far.
Cut it off and replace with a hose clamp - or put it back in place and make certain to lock it?
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| | | Linkdog | | Thor | |  | | Reg. Date | : | 10/02/2011 | | Posts | : | 2,972 | | Location | : | Groveland, FL., United States |
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| | Posted : 28 Jun 2024 - 23:34 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | That sucks, When I read the title I remembered what happened to the wife and myself a few years back. Went to the gas station to fill up did the pay at the pump and with nozzle in hand pressed the 87 button without realizing that someone before us locked the handle full on and both of us got a shower luckily we were only a mile from home. New habit from then on is to check the handle first. As to your question no I've never had the tank disconnected .
| Never drink from a cow with one udder! 2010 1600 Blue&White ( of course ) Long TORS and HP filter.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 29 Jun 2024 - 02:57 Post title : Re: $12 of gas on the ground (Re: Linkdog) | | | 
The above connector located under front of tank - failed, showering engine with gas.
(See Service Manual page 10.86-10.87.)
Connector was still in place when I raised the tank, but was loose and slides off without having to release it. Sprays fuel when under pressure, drips with engine off. Failure was sudden. Replaced it with the smooth-body hose clamp in pic that can't damage 5/16" fuel line. Recommend replacing this connector with a clamp next time you raise your tank - nothing lasts forever.
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| | | Leethal | | Zeus | |  | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 29 Jun 2024 - 06:14 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | What has failed? Seal, clips?
| Experience is something you get just after you needed it 
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | Linkdog | | Thor | | | | Reg. Date | : | 10/02/2011 | | Posts | : | 2,972 | | Location | : | Groveland, FL., United States |
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| | Posted : 29 Jun 2024 - 19:12 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | Nothing else is easy on this thing so why the quick disconnect?
| Never drink from a cow with one udder! 2010 1600 Blue&White ( of course ) Long TORS and HP filter.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 30 Jun 2024 - 02:22 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | Blue connector was on the end of fuel line, connects line to steel nipple from tank. It's shown open, with blue section pulled down "unlocking" and exposing black buttons on each side. Normally, you slide blue part down, then squeeze the buttons together to release line from nipple. Mine was loose enough that it just slides on/off without having to do any of that, so no compression on nipple - just a loose hose.
I think rubber under the buttons got soft and gave up (after 15 years). Clamp is much more positive and problem solved. No more gasoline bath. Happened suddenly, too, did 75-90 miles the day before, was parked in the shop, not a single drop on the floor and not a whiff of gas. Fuel line stayed in place but connector went limp and leaked.
Fuel line "double check clip" connector (blue) locked in place on steel nipple under front of tank
Why the quick connect fitting? Dunno, was stock. Kind of an over-engineered solution, especially when you realize it was fastened to fuel line with - you guessed it - a crimped-on hose clamp.
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| | | Linkdog | | Thor | | | | Reg. Date | : | 10/02/2011 | | Posts | : | 2,972 | | Location | : | Groveland, FL., United States |
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| | Posted : 30 Jun 2024 - 15:12 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | Not a big deal in " the old days " but now the fuel is under pressure. Good thing you were not in the middle of the Mohave
| Never drink from a cow with one udder! 2010 1600 Blue&White ( of course ) Long TORS and HP filter.
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 01 Jul 2024 - 00:03 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | Yes, I have had my tank off countless times, no issues as yet. Do you use any ethanol blended fuel?
| Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 01 Jul 2024 - 16:42 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | I may have jumped the gun - Linkdog is right, went at it the old way without concern for pressure (45-90psi).
After installing hose clamp (in pic), gave the bike a bath and wax, gassed up and went for a ride. Didn't get far - sitting at a red light I saw gas drooling onto exhaust pipes. Wasn't spraying everywhere, but still leaking. Siphoned out 5 gallons and it's back in my shop.
Finally found OEM fitting listed with injectors, hose assembly is $200US.
About to lift tank again, might try running motor to see the clamp leak, as I can't believe it isn't holding pressure. There are no less than 4 garden variety hose clamps after pump inside tank on filter, curious to see clamp on other end of line (posted pic of pump assembly earlier). Tank fitting has a wee-tiny O-ring doing all the work, apparently common on injected bikes.
Ordered stock hose, #15 under Throttle Bodies, part # T1246100. Should be good for another 15 years....
To answer question re fuel here in California, we went thru the ethanol nonsense many years ago, took out fuel line in my Jeep but never affected the Triumph. "Premium" is a measly 93 octane here, best I can do.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 01 Jul 2024 - 20:44 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | It gets better....
According to a rather nasty note from supplier, part# T1246100 has been superseded with new part# T1246199 - both on backorder.
Thanks to an Aussie's post on eBay, I suspect new part number will never be available and is merely a ticket to oblivion. Here's photo from his eBay listing showing the problem:
Those hose clamps at each end are installed with a hydraulic press and cannot be removed, designed for high pressure.
Therefore, fuel rail, hose and tank disconnect are all constructed as a single unit. Even if the #15 hose assembly were available (for $200), how are you gonna fasten it securely to the fuel rail without a leak? So, no, #15 will never be available, it's a dead end. Tell me I'm wrong.
Only solution I can think of is to double or triple clamp tank spigot and tighten the crap out of 'em.
As a side note, I'm seeing vendors on eBay selling "high pressure injector hose clamps" that happen to be the exact same ones I got at O'Reilly auto parts the other day (in previous pic). Where's Mat when you need him? Anybody got a better idea?
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| | | Linkdog | | Thor | | | | Reg. Date | : | 10/02/2011 | | Posts | : | 2,972 | | Location | : | Groveland, FL., United States |
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| | Posted : 01 Jul 2024 - 22:08 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | Hydraulic shop maybe? That's the route I went when I needed an extended brake line. There has to be a solution for this. Or look at other models of Triumphs, their all EFI.
| Never drink from a cow with one udder! 2010 1600 Blue&White ( of course ) Long TORS and HP filter.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 02 Jul 2024 - 03:25 Post title : Re: $12 of gas on the ground (Re: Linkdog) | | | I brazed a fitting on front brakes and installed a longer line way-back-when, forgot all about that....
But, stock tank connector is not available alone, and mine is shot, so hydraulic shop is not an option.
Now that I have tank raised and hose off (again), I can see that the clamp I used was too small (bit into hose and deformed). So, I just installed a bigger 16mm version of same clamp. There's not a lot of steel tube to clamp onto, it has a stop but no barb at the end:
Out of curiosity, I ordered a few clamps from Hermys in Pennsylvania; these show as #14 and appear to be included with (unavailable #15) $200 hose. Wondering if there's anything special about them - or if they even exist. Meanwhile, might fire up the engine with tank raised and see if it's sealed this time. Hoping to avoid digging into fuel rail to solve a simple problem.
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 02 Jul 2024 - 05:34 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | Have you looked around to see if anyone is wrecking a Tbird, might be the easier way out.
I would be visiting a fuel injection specialist and see what they come up with. A pipe with no barb and a clamped hose could be very dangerous.
| Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 03 Jul 2024 - 03:30 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | You are correct yet again. There's no way a hose clamp would stay on that short, barbless nipple from tank. Could be lethal. ;-)
Back to the drawing board, I'll look for a fuel injector guru around here, good idea.
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 03 Jul 2024 - 06:19 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | Good luck and keep us posted.
| Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | MotorMac | | Jupiter | | | | Reg. Date | : | 29/08/2010 | | Posts | : | 1,868 | | Location | : | Nor Cal, United States |
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| | Posted : 04 Jul 2024 - 04:14 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | Good news: This should be the end of this thread (talk about a rabbit hole...) Bad news: Dunno what caused the failure. Might have been my fault for not securing the connector a year ago when I replaced fuel pump - maybe it hung on for a year. Or...? Can only guess.
Conclusions from this (needless?) adventure: 1) there is no way to connect fuel line to tank other than OEM connector. 2) Replacment OEM connectors are not available, either alone (no part#) or attached to the $200 fuel line (#15 in Throttle Bodies list), no matter which of the two #15 part numbers you use. 3) Triumph parts are a mess, and some dealers are dialed-in while others are clueless.
Out of desperation, I cleaned up my old OEM connector (which has a barb, BTW), slid it onto tank nipple and heard it click before latching! Found proper hose clamp (these are now listed as "high pressure" in auto parts catalogs), put it all together and it works. Only damage was loss of 3/4" cut from fuel line to free connector. Here's the winning combination:
Correct clamp is stamped 14-16mm. Tightened it up until screw head met nut and it could go no farther - it wasn't stressed and produced a nice bulge on OEM connector's barb in very thick OEM hose. Solid, problem solved. Just make sure clamp starts and tightens properly.
These clamps have a pointy end that slides around inside against hose as it tightens (red arrow). If tip bites into hose, clamp will deform. If it goes as it should, tighten 16mm clamp as far as it will go, then cut off excess bolt to avoid tangle with nearby wiring harness and keep it from ever loosening. It's not coming loose.
Would still like to have a new connector on hand, if Triumph would sell them. Will look up an expert, these might be available elsewhere.
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 04 Jul 2024 - 06:56 Post title : Re: $12 of gas on the ground (Re: MotorMac) | | | All good info Michael, glad that you have it sorted. I bought a S/H set of throttle bodies a while ago, boxed them up for storage. I will have to check them and see if a connector was included. 
| Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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| | | Linkdog | | Thor | | | | Reg. Date | : | 10/02/2011 | | Posts | : | 2,972 | | Location | : | Groveland, FL., United States |
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| | Posted : 04 Jul 2024 - 13:07 Post title : Re: $12 of gas on the ground (Re: Leethal) | | | As a last resort could this be fixed with a flare fitting?
| Never drink from a cow with one udder! 2010 1600 Blue&White ( of course ) Long TORS and HP filter.
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| | | Leethal | | Zeus | | | | Reg. Date | : | 24/01/2011 | | Posts | : | 6,526 | | Location | : | Australia |
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| | Posted : 04 Jul 2024 - 21:57 Post title : Re: $12 of gas on the ground (Re: Linkdog) | | | Possibly yes .
| Experience is something you get just after you needed it
1600,Foran Razorbacks, Meerkat bypass, Dyno tune, real headlight,plenty of chrome,switchblade pegs, Nitron R3 shocks & Ikon progressive fork springs etc. Scorpion Western Low handlebars. PH adjustable fork caps.
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