GTX Fuel Leak
I've had a problem with adding fuel to my GTX. If I fill it right up I get a large fuel leak down the left side of the tunnel and down the left foot rest. Not sure if anyone else with a REV chassis has seen this problem. I pulled the seat off on the weekend and it looks like the large fitting for the Injector Fuel Lines and leads isn't seated properly to the top of the tank. Not sure if it's something I can repair or if it needs to go back to the dealer? :?:

I'm carbed, so I don't know the differences in fuel delivery between that and SDI, and have to say I have never looked that closely into it on my sled, but after about 3500 miles I have no leaks and believe me, I have on numerous times squeezed every last drop in her it would hold. Could it be something that has worked itself loose?

Hard to say for sure, but it sort of sounds like some kind of fitting on the tank or the line itself for the tank vent line is damaged. Usually the vent line is a plastic fitting that screws into the tank and is adjoined to a small see through plastic hose, coiled up around the air box or handlebars. I would guess that the leak only being when the tank is full is coming from the vent lines and not the fuel pick up as it would be doing it all the time. One other thing to note is that the fuel tank on a Rev extends under the seat. When you sit on it it will push fuel out if the cap isn't on. Maybe the cap doesn't have the little rubber seal under it or doesn't seat properly. If you look at the base of the ring around the cap, there is a little hole. maybe the line from that makes it into your left footwell.

Well, I got the fitting loose and the gasket has a step that needs to properly fit the opening. It's very easy to get it cocked and then it's going to leak sooner or later. I carefully reseated mine and held it in place while screwing the large retainer ring back down. Sure enough... the fitting now looks level where it looked cocked before! I'll pick up a couple jerry cans of fuel this week and fill her up to see if the leak is gone. Time to get her out of storage anyway!