Fuel tank vent lines

Hoping someone may have experienced this before and am looking for some direction. I recently purchased a 2008 800 ABS model from the original owner with 4200 kms on it. He indicated at above 5/8 of a tank fuel would flow out of the hose under the bike which I verified. He was not mechanically inclined, and the bike was rarely ridden, neglected in a dusty garage. My first thought was that there may be a crack in the vent line, or it may have become disconnected thinking it was rubber based on the manual I have. However, after looking a little closer it appears that the line that is leaking is a hard line that ends up near the filler neck. It is the smaller of the two lines in the tank. It looks like it's a crimped/soldered copper line using my borescope with a transition to rubber under the tank. Before I remove the fuel pump for better access, I thought I would ask if anyone has experienced this..

 

As I expected there is a hole in one of the hard lines in the tank. My initial thought was that it was the vent for the tank, but it turns out it is the overflow drain line. I hung the tank from the ceiling and had the front of the tank pointing downward. I then filled it up with some water just enough to cover both the lines in the tank. With a short piece of hose, I blew into the tank and saw the air exiting the overflow pipe into the tank (with my finger blocking the hole at the top of the tank). I still need to get this fixed but for now at least I can temporarily fix the problem by plugging the overflow hole in the fill cap. Less than ideal but trying to avoid spending $ 1000.00 on a new tank for the cost of a rubber stopper. I located a repair shop in Toronto, Gas Tank Exchange. I will see if they can do the repair, their website says they repair motorcycle tanks. Otherwise, I will have to wait to cash in my empties for a new tank, hope my liver holds out!

 

I suppose if one was creative one could cut the tube and insert a fuel resistant rubber hose.....

 

Possibly the rubber hose would work but I think for now I will just plug of the line until I can find another silver tank. Disappointed as the tank is mint and Gas Tank Exchange is unable to repair the tank.

 

A photo would be helpful

 

I have temporarily fixed the problem by inserting a smaller piece of line inside the overflow connection on the bottom of the tank. I then installed a # 10 x 1/2" SS screw and applied some RTV for insurance. No leaks in the makeshift plug so far after a full tank of fuel. My suspicion is that the bike was left outside for at least one winter and water settled in the overflow line, froze and burst the pipe, northern Alberta hits - 40C/F regularly in February. From the picture you can just make out what looks like a bulge in pipe, it was difficult to get a picture inside with my phone but the arrow points to where the hole is. The surface rust inside the tank would indicate the fuel tank was stored for a while with a less that full tank for a period of time. Just have to keep an eye out for a used tank now.

 

Well done finding and fixing that