The water drain hole where the tank filler cap lock fits on my 03 Multi is blocked somewhere, anyone know where the pipe run is and where does it exit?
I had the same problem with my 996, caused all sorts of problems with water in the fuel etc. This ocurred whenever I opened the fuel cap to fill up. Water would collect around the filler and surge into the tank. so that means problems after each wash and following heavy rain! You may be lucky and clear the blockage with a carefully applied length of wire coat hangar or copper wire, however....... Inside the tank there is a length of fuel pipe that runs between the top and bottom of the tank. There is a second drain hole on the bottom of the tank which passes to the outside of the tank. Draining water therefore passes through the fuel tank and out of the bottom. At the bottom of the tank a length of rubber tube runs from the bottom of the tank, down to the bottom of the bike for the water to drain away. By lifting the tank from the bike, you will be able yo locate this tube. It is simply a push fit onto the "male" attachment on the bottom of the tank. there are no fancy connectors as it is under no pressure. It is the only one of the three pipes push fitted. Having found said pipe, remove it and gently blow through it. No probs as no fuel passes through only external water. Obviously of you can blow through it easily, no blockage here, The most likely place for a blockage to occur is at the bottom of the tank where it passes to the rubber tubing as the aperture narrows slightly . The most thorough way of clearing the debris is by running the tank to almost empty, taking it off the bike and carefully spending time cleaning the entry and exit points with said sturdy wire. Unfortunately in my case it was the internal pipe itself that was bunged up with so much crap there was never any chance of water passing through the drain. I had to replace the length of internal fuel pipe which required removal of the fuel pump assembly from the tank. Not too bad as at the same time I replaced the fuel filter and had a chance to inspect the internal condition of the tank. If you have to go down this route dont forget to replace the large O ring around the fuel pump assembly with a new one. Costs pennies In honesty, its not a major job as long as you take your time and once its done you will have the satisfaction of knowing no more water is going into your fuel and the associated running problems.
Harry, there are two rubber pipes which exit at the lower front left of the engine. One of the pipes is the drain - it goes up to form a y-piece where it splits into two tubes. These go on to the underside of the tank - you'll be able to see the one on the left hand side, the one on the right is just above the cam cover. The internal plumbing of the tank to get to these points is a little complicated!
