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Discussion Starter #1
Here's the story, followed by the questions:

1. 2009 K1200LT with 15k miles on it. I have filled it up 31 times since I bought it September 2011 with 9,200 miles on it.
2. A couple of days ago, after parking it in the garage, we heard a strange thumping sound coming from the front end every 30 seconds or so. We listened carefully and determined it was coming from the gas tank. I opened the gas cap and heard the "whoosh" sound of in-rushing air. OK, so apparently I've overfilled the gas tank and the canister is plugged with gas.
3. Replaced the gas cap and it started and ran fine. Forgot all about it, thinking I had dodged a bullet, until...
4. I ran out of gas on the side of the road. But wait - the fuel gauge still shows a half tank of gas. ??? Removed the gas cap, "whoosh" is heard again, used flashlight to observe no gas in tank!
5. Removed the canister along the side of the road (thanks to directions I had printed just the night before from this site, because I knew I had the problem), put some gas on board and rode home.
6. I've filled it up twice since then. After fill-up, the fuel gauge indicates "full", it slowly works its way down to "half", then stays there for the remainder of the tank of gas. The bike runs fine otherwise. Currently, I'm using the trip odometer to tell me when to get gas. That works, but it's not convenient.

Have I damaged a float or something that is used by the fue gauge?
What's it cost to replace that? (at a dealership)
Is this replaceable under warranty? (please say "yes")

PS: I had to think about why this never happened on the '05 LT, on which I put 120k miles. I've been filling up the '09 the same as I did the '05 - which involves a lot of "topping off" of gas, after the automatic shutoff. It's because I had the canister removed at a tech session after I'd had the '05 for just a few months, so I never learned that what I was doing was adding too much gas.
 

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When my 09 was 9 days old it left me by the side of the road. Long story short, the fuel sensing strip had to be reset. Warranty paid for service, lodging, meals but not a days lost wages. Any how, gauge said 1/3 tank and 80 miles to go but, was bone dry.
 

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I guess I've been real lucky, accidentally overfilled the 09lt a couple of times with no trouble.
 

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2005 K1200LT
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You know Howard there is a disconnect point on the hose right under the pillion seat. Hope you didn't go all the way under the top case to do this. If you can't get your sender straightened out let me know I have an extra one.
 

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You're gonna have to go in deep Howard ! Pull the guts out of the fuel tank and the damage will be obvious..

You know if it was me I'd try to repair it....

Good luck brother.. That fuel pump will cave the tank in pretty good...

John
 

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Howard I think it's time for another tech session at your place? Not that I have the skill to fix your issue, but I can sure ad moral support or bring some food to cook.

I have not done the canister thing on my 05 yet, might be time to think about it.

Glen
 

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Discussion Starter #9 (Edited)
14wntr said:
OK, now we're talkin'! This photo was in that thread, and explains a lot to me. I assume this is what has happened to my fuel gauge, as the same problem was described in your thread. Thanks.

Dumb question: I assume the body panels and tank have to be removed, in order to remove this thing? In your photo, I see the tipover wing cover, etc., on the shop floor. Sure would be nice to not have to do all that to fix this problem.

<edit> I went back and reread the thread that Mike provided the link to. I understand a bit more now. Thanks, Mike.

 

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Discussion Starter #10
jzeiler said:
You know Howard there is a disconnect point on the hose right under the pillion seat. Hope you didn't go all the way under the top case to do this. If you can't get your sender straightened out let me know I have an extra one.
Nah - in for a penny, in for a pound... right? We had the top case, plastic panel, and passenger seat off - all by the side of the road (actually, we pushed the beast down the road about 100' to a nearby driveway, so we were better off than on the side of the road. You should have seen us: my Gold Wing buddy Steve was pushing the LT, with me on the seat (kind of), leaning off to the left and paddling with my left foot for all I was worth. :eek: We did the complete canisterectomy (per that Word doc provided previously), except for removing the tube that goes down by the rear tire. I'll do that sometime soon.

I'll try to straighten out the "tube" thing ("sender"?) on my own, or I may see if a dealer will do this as a warranty repair. The factory warranty is still in effect.
 

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Discussion Starter #11
JPSpen said:
You're gonna have to go in deep Howard ! Pull the guts out of the fuel tank and the damage will be obvious..

You know if it was me I'd try to repair it....

Good luck brother.. That fuel pump will cave the tank in pretty good...

John
Thanks, John. I'll take some photos if I end up doing the work.
 

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Am I understanding correctly, that removing the canister can possibly prevent this? I'm currently riding with my trunk off but my wife wants to ride tomorrow so I will need to put it back on. I guess today might be a good day for a canisterectomy. Off to the Halls of Wisdom.
 

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Discussion Starter #14
dandnfr said:
Am I understanding correctly, that removing the canister can possibly prevent this? I'm currently riding with my trunk off but my wife wants to ride tomorrow so I will need to put it back on. I guess today might be a good day for a canisterectomy. Off to the Halls of Wisdom.
Yes, removing the canister will prevent this problem.

Not over-filling the tank will also prevent the problem, but I'd rather have my appendix out at the first sign of trouble than have it removed after it ruptures. BTDT. Not a good time.
 

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Already had the trunk off so it was very easy to do. I guess an ounce of prevention...
 
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