I cried today......

[Scott-(Altoona, PA)]

no tears but still I silently cried while setting on the street in front of my house. Lets back up about 6 weeks. I get my XII out of winter storage take it to a gas station and fill it up (a tad too much so I splashed some in the overflow/catch cup under the cap). Short ride (only 5-6 miles) and home again so I can go along with the family for a "thing"! Ride it to work a few days and then it snowed. Two days later it snowed again then rain for a week and a half to two weeks. Then I get home from work and my wife needs something from the grocery store, no problem the Voyager is out front waiting. I jump on it and along my ride I realize the low fuel light is on.
Get in the store lot, open the gas cap and shake the bike no sloshing sound, no gas, odometer says I've put 25 whole miles on it since I filled it, so now I really scratching my head in wonder.
I've been smelling fuel but assumed it was from the overflow when I filled it. Now, I know that assumption was wrong.
I can only open the #3 and #4 float bowls to drain them checking to see if there is something stuck, can't reach the #1 or #2 so the next weekend I make a trip to Harbor Freight and buy Allen-head sockets so I can reach the first two. Still nothing, put 2 more gallons of fuel in it and drive it for a 15 mile trip, everything seems to be right in the world. Still not convinced I decide to let it set a few more days and watch, still smelling gas but can't see any spots under the engine/tank. I pick up a (FRAM- Part #G2 ~ Dollar4dollar) fuel filter and get my tools out. I've read quite a few threads concerning the who's and how's of changing our a fuel filter, I pull out my printed PDF file of the Service Manual and read through chapter 2, pgs 16, 17 and so on. The service manual advises removing the fuel tank to provide extra room/access but others have done this simple task without doing so, so I will just skip that task. I managed to get get my hand on the fuel filter (which looks original, w/47k miles on it). Just as I'm assessing the length of the fuel lines attached I start hearing some fluids flowing, tilt my fat head down even farther and to my surprise the line has pulled free from the tank. NOW I have to remove the take to gain access to the fuel port.
Back to the service manual, SM 2-17 Removal of Fuel Tank. Fairly straight forward, remove rear shocks, disconnect sensor wires and remove rear frame bolts.
Insert Brain FART Here!

[Scott-(Altoona, PA)]

While systematically removing the bolts identified, everything is going smooth and I'm seeing a tad more room under the tank. then as the last bold is removed the entire center of the bike collapses and the bike is now broke. BROKEN RIGHT IN HALF! and I cried tearlessly even more (I won't tell you that I swore also but you can safely assume). Then I realize the error of my ways, I tried to do something myself without adult supervision! Dam, dam, dam, not knowing what to do I ran to the shed grabbed my little HF floor jack and old car frame jack and hustle back. Quickly I jack up the center of the bike from the right side and attempt to reassemble the left side. Use the car jack to raise the other side and work back and forth from point to point, bolt to bolt. Some successes and some really frustrating moments. Knowing its Sunday afternoon I don’t want to bother anyone but what can I do? I try to text Mr. Leo asking if he has time for a call, 15 minutes and no answer so I know he’s busy. He has a life and is trying to enjoy it so I can’t be upset with anyone but myself. I call my bike inspection mechanic and ask if he has time to help. An hour later he shows up, with his knowledge the bike is whole again frame straight and all bolts where they should be & under 20 minutes. Most of which was me telling him my sad story leading up to my plea for help.

Oh and the fuel smell was apparently (hopefully) the fuel line on the bottom of the tank dry rotted at the end and falling off, I trimmed it and make certain it was on as far as I could get it. Plus I made sure the clamp was over the bulge/ring. I think it was leaking/dripping down onto the cross number piece, along the shaft and down by the rear wheel. That was the only spot that seemed to be damp too by the way (remember nothing under the engine or tank).
So it's back together, tomorrow I get to put some gas in it, Seafoam and test drive it again!
Please pray for me! Please! PLEASE!

[jre258 in SoDak]

I had the fuel line from my tank to the filter do the same thing on my '90. I think I got enough room to get under the tank by removing the bottom bolts on the shocks and letting the swing arm drop. It was tight but I managed to get the new hose on and the hose clamp in place.

[mountainman]

Been there! Here's a great tool for that job. The fuel lines are a silicone type and you can squeeze fuel line shut and or work with fuel line as in assembly. I use these on mine, in fact I carry about a 6" length pair in the bike for emergency's. These can be used to shut fuel off by pinching line shut to stop a leak while its being fixed. These things will reach back in where you can't. I also carry 11" lnt. 45 degree needle nose pliers.

http://www.harborfreight.com/10-1-2-hal ... 65711.html

[Bruce in OK]

My bike ('01) had the same issue in the second or third year of ownership. I don't remember what I took off to wriggle my hand up in there to trim and re-attach. I do remember it was a tough chore. It is probably time to replace it again. I've got the same issue on my '86 Honda Fourtrax right now....

[k7nutN7nut]

Knowing its Sunday afternoon I don’t want to bother anyone but what can I do?

Scott, I feel for ya man, I felt like that a few times getting the engine swapped in my '00...only because I was not familiar with the Voyager yet!?
But when it comes to Sunday(The Sabbath), remember the "Ox in a ditch" clause...if you need help brother!
I'm glad you got 'er figured out, with some help and that helped me too, now I know what/how to deal with the situation, but I hope I wont need a new filter for awhile?
Or a fuel line for that matter?

[Gator Mike]

When I had the engine out for tx problems I changed all the fuel lines. It was easy with the engine out but I can see where someone might come close to losing their religion with the motor in..........Gator Mike

[richardb, austin]

When you get her running, come back to Texas & get out of that darn snow - that's what's causing the problems.

[Scott-(Altoona, PA)]

Richard, I got it back together and running. But as for moving to Texas, I don't see that happening any time soon. As a teen I cut grass for a elderly fellow (born in 1899) who lived in Texas for a while, he told me "don't believe what they say, when the say it's dry heat so it don't bother you!" He would follow that with "heat is hot, wet or not!"
I could only laugh when his son who lived in TX offered me a job there. No I'm content living in PA, thanks anyway!