Fuel leaking from the altenator cover!!!!

[Abaton7]

Hello from Hartland Vermont! I'm working on an 82 GS 650 with 4700 miles on the clock. She ran great last summer! But this year I noticed fuel leaking from the fuel filter line, on top of the starter cover. I was running it and I saw fuel bubbling out of the gasket of the alt cover. I took off the cover, and got about a quart, or more or of raw fuel from in where the alt is. I thought this cannot be good! I'm sure that fuel should not be in there. Any thoughts / ideas would be greatly appreciated. Thanks!

 

[rphillips]

First... Welcome. 2nd I've never heard of a fuel filter line on a GS. 3rd, check to see how much oil in eng. crankcase Common for gas to leak through pet cock and into crankcase, normally when left in PRI. position. Ask me how I know. A gal. of oil with 4 gal. of gas in it looks like pure gas.

 

[Rich82GS750TZ]

PO certainly could have installed a fuel filter. Many do. It didn’t come from the factory that way. The fuel line should run directly from the big nipple on the petcock to the center nipple on the fuel rail in the rear between carbs # 2 & # 3. It’s a short run and all downhill. I can’t imagine I the scenario where a PO somehow managed to run this line, for some reason, into the stator cover (I’ll assume that is what you mean by alt cover. If the fuel line is running as low as the starter cover, I can’t see how the carbs would ever get enough fuel.

Your engine is full of gasoline. Do not attempt to start the bike. Drain the oil. Fix the fueling problem. Then refill oil and replace the oil filter.

Picture are often helpful.

 

[Abaton7]

​pic of starter cover with stain from leak

 

[Abaton7]

fuel hookup.........​

 

[Abaton7]

This was full of oil and gas, maybe 2 qts​

 

[Abaton7]

I installed the fuel filter because the tank was rusted inside, and needed a good cleaning.

 

[tom203]

The 650 shafties are plain bearing crankshafts …..they won’t like working with oil contaminated with gas….so change oil. Obviously, find gas leak. Be suspicious of petcock, so check for its correct operation….if it fails, gas can leak down the vacuum line on #2 carb spilling into #2 cylinder and onto crankcase.

 

[Rich82GS750TZ]

Oh, the fuel is dripping onto your starter motor cover. I read it as somehow your fuel line was running into the stator cover. Reading comprehension has never been my forte. Pics help. Thanks.
So, besides the drip coming from one or both sides or your in-line fuel filter and slowly tarnishing the starter motor cover, is it also running under that cover, through the starter motor seal, filling your crankcase with fuel? or is it running through the stator cover gasket. That seems unlikely, but you've got to fix that drip. Where is the drip coming from
If the drip isn't from the fuel line, you'll have a determine if you have a condition that is allowing fuel to flow directly through the carbs into the head, down the cylinders, and filling the crankcase. This could be faulty petcock, or one left on prime, faulty float needles/seats in the carbs (they don't do such a good job of completely stopping flow even if in top condition), or a combination of the 2. OK. no I'm rambling.

 

[rphillips]

By golly, I can sure understand it all now. The drip on the starter cover has nothing to do with the gas in the dyno cover. There is big drain hole for water or gas to drain out the bottom of the starter area. Did you check the eng. oil level? What did you find? that's where the fluid in the cover comes from. If pet cock wasn't left on at some time, it needs fix'in... Just my opinion.

 

[Abaton7]

Oh, the fuel is dripping onto your starter motor cover. I read it as somehow your fuel line was running into the stator cover. Reading comprehension has never been my forte. Pics help. Thanks.
So, besides the drip coming from one or both sides or your in-line fuel filter and slowly tarnishing the starter motor cover, is it also running under that cover, through the starter motor seal, filling your crankcase with fuel? or is it running through the stator cover gasket. That seems unlikely, but you've got to fix that drip. Where is the drip coming from
If the drip isn't from the fuel line, you'll have a determine if you have a condition that is allowing fuel to flow directly through the carbs into the head, down the cylinders, and filling the crankcase. This could be faulty petcock, or one left on prime, faulty float needles/seats in the carbs (they don't do such a good job of completely stopping flow even if in top condition), or a combination of the 2. OK. no I'm rambling.

I'm pretty sure the leak was from a loose hose clamp on the fuel filter. I put gas in the tank last night, and see no gas leaking today. Maybe the F.C. WAS left on prime. She ran fine all last summer

 

[Abaton7]

I found a stator cover gasket on Ebay for $6.00. Thank you for all your replies!

 

[Cipher]

Is a stator cover gasket available,? OR do I just use permatex gasket maker? I cleaned both surfaces with a small wire brush on my drill. They are spotless. I think a gasket would be better, but I have had good luck with the permatex. Thank you for all you replies!

Get a gasket. Thickness being of some import.