Originally Posted by cwf
Your experience reminds me of the first time I bled the clutch on my 2000 K1200LT. I installed a speedbleeder in place if the grub screw and I boogered up the connector at the end of the bleeder line . The only way to replace the bleeder line was to pull the entire rear end of the bike (swing arm too). The dealer wanted over $600 so I did it myself. Learned a lot about the bike!
Of course there wasn't one clutch bleeder line in the United States. Took a month for the Fatherland to ship me one (middle of summer and very fine riding weather!)
So so as to not repeat that ugly experience...what words of wisdom would you care to share. I would be thankful unless the memories are too painful!
1. Do not replace the plastic "Quick Disconnector" on the fuel tank plate with anything - metal or otherwise. Leave it alone!
There is no O-ring in it to bother with. Mine had some special sealant that BMW used on the fitting. The new metal one bottomed out (it's a pipe thread) and the plastic it threads into was spread and had some small cracks in it too. It leaked while riding and I noticed my mileage dropped and I could smell gas every time I stopped. It also leaked gas onto the ground and all over the left side of the engine around the shifter area. I ended up with some $400 borescope (there's a video on this site somewhere about it) to snake into the crevices to find the little leaker (at the Q-D on the fuel-pump plate). The thing soaked the fiberglass insulating mat to the point it dissolved the glue that held it onto the tank's bottom.
Luckily, the thing didn't burst into flames while riding it. The replacement plastic fuel-pump mounting plate is $500 and has the same plastic fitting glued or sealed onto it. Older bikes around the 2000 yr. had metal pump plates and you could screw fittings into them and they would distort nor crack. I reiterate "Leave it alone!"
You might replace the O-ring on the mating plastic male connector, or replace that one with metal. BMW doesn't show that O-ring on their GT fiche, but it is the same O-ring as used on a GS (I think that's what Lily at Ozzie's BMW said?).
2. Do not seal up the tank
for fuel leaks while it's off the bike, allow it some breathing room. Mine swelled up to the point it would not fit back into the bike's frame. New gas tank is nearly $1000. Of course, it being over 100 degrees outside didn't help either. Took a lot of steaming hot and cold towels to reform that tank to fit back in the bike's frame.
While you're messing with the tank, take a look at the very back end of the tank. On mine, there was some metal clamp on a large hose that was digging into the plastic gas tank. I loosened the clamp and swung it around so it didn't make contact. Seems the tank has been on and of the bike so many times for sundry things like air-boxes, idle controllers, sensors, whatever, that it was getting gouged into pretty good from all the removals. Of course, my re-engineered and newly fattened gas tank now holds more fuel than stock and I plan to sell it to Meese for $3000 too.