RSV Mille leaking gas baddly

One of the pipes in the tank has broken. You need to repair the broken pipe or get a second hand good tank.

The purpose of the pipes a one is a breather, and the other is the drain for the fuel tank filler.

Ethanol additives have done this, there are threads on this problem

http://apriliarsv.com/aprilia-rsv-mille/22592-leaking-fuel-tank-vent-pipe.html

Take off fuel pump and repair with ethanol resistant repair pipes, it not easy, best option is a new tank.

https://www.apriliaperformance.co.uk/fuel-tank-breather-kit-only-to-fit-rsv-metal-tanks.html
had the same problem.
used the supplied clamps near the fuel pump but not by the filler as made me too angry to get them to fit so didn't use as seemed tight enough without them
hess

Perhaps you should remove your tank to get a look inside it? Can be tight fit at the front against the yoke so a second person might be a good idea. When you lift and prop the tank by undoing two bolts near the top yoke the main fuel line is easy to spot on the other (left) side - and just clicks apart. Any leaks here? O-ring gone? No. Another fuel line connects at the base of the tank with a 17mm banjo bolt. Leak there? No. Disconnect both these fuel pipes and wiring to loom so you can remove your tank - by unbolting the whole bracket that it hinges on (or withdrawing the pivot). Remove the plate-like assembly from the base of the tank. You withdraw filter, sender, etc. as one. Mind the gasket; I reused mine. I had a slower leak right there where the line connects to that plate so replaced that first section of main fuel line running to lift side of machine and its clips. You can now look up inside your tank which will probably be resin (2003). The two pipes in my nylon tank (2000) look like umbilical cords internally and are a 1. water drain and 2. a breather for fuel gases. They run from under the fuel filler cap down to the bottom (right side) corner of the tank. Damage here? I had corrosion of the alloy nipple due to a blocked water drain left too long. The drains extend from there down to where you photographed and labelled 'Male X/Y'. On reassembly check these are kept off your hot exhaust. Could the breather pipe really be broken INSIDE the tank?? Just rambling on as I was at this recently. Hope you get sorted easily as some of the parts s/h are expensive.

Fuel leak

teemu95 said:

So my 2001 aprilia rsv mille with 36tkm under its belt started leaking gas. Badly. I'm no mechanic but I took off some fairings and found out the gas pours out from a tube near my crotch. It poured out maybe 4 liters after i filled the tank and then stopped all good.

*couldn't upload pictures for what ever reason, so made links to them

The bigger picture: http://puu.sh/ALaTp/27ee6bce1c.jpg

So the location of the leak is at the bottom of the tank near my crotch.

The leak: http://puu.sh/ALaUG/d845554653.jpg

There are two hoses that look identical. One of them is the leaking pipe and the other just sits there looking innocent as ever. The male adapters look like a perfect match to the two tubes but they only seem to lead to bottom of the bike, directing the gas leak out of my legs. What is the purpose of these pipes and what is the problem?

Click to expand...

Sounds like the rubber fuel hoses in the tank have failed. you need to remove the tank, turn it upside down, remove the fuel pump panel and replace the internal hoses on the fuel pump. you must use fuel resistant hoses NOT normal fuel hose as this just melts if submersed in fuel. your local Aprilia specialist or dealer will be able to supply you with this.. If your tank is plastic please be aware they are a bugger to re-seal as they slightly deform with age. if your not confident get a qualified person to do this for you.

Has anyone actual experience of seeing normal fuel line perish after a certain period of immersion within the tank?

Yes, they are not ethanol resistant, and will fail .

https://www.apriliaforum.com/forums...T-HOSES-Follow-up-on-my-inner-tank-vent-hoses!

with the metal tank they are replacable 1999. On later bikes the whole tank is plasic and will rot out, expand, break. The drain pipes go first inside the tank and it causes a leak. Some people block the drain pipes, but it will fail.

http://apriliarsv.com/aprilia-rsvr/5629-fuel-tank-leaking.html

pictures here show plastic pipes that have failed. The rubber pipes to the pump.also fail because of ethanol. The uk is alowing 10% ethanol into fuel and MUST avoid it.

Drat! Thanks for that, Hertsrsvr. Since reading your comment been on a Norton owners site and Pistonheads etc. searching around the topic and yes, it appears its well nigh impossible, or soon will be impossible, to buy ethanol-free fuel. While some older vehicles may well be unaffected I can see why our Milles could be vulnerable. This also begs the question about which tank materials are more / less resilient to being dissolved. I know they are said to have changed over the model years from steel to resin to plastic, yes? Clearly 5% alcohol biofuel has been present in our petrol for some years (I didn't know) and I can see its action as a solvent - and its hydroscopic properties - could be an issue over time. I'll certainly attempt to avoid E10 fuel now by buying premium fuels. My RSVR is 18 years old with less than 15K miles and after a fair bit of use from 2004-09, I've had it sitting empty of fuel for long periods between use. This may have helped delay onset of such problems. Lately since smelling a fuel leak I'd emptied its tank (c. 2016) and SORNed it for another year+. My leak has stopped but from what you say it sounds like my recent repair with standard fuel line needs redone with SAE 30R10 at some point. I am now wondering if an earlier problem with sticky throttle bodies had been due to deposits left by fuel. Gives me plenty to think about and discuss with mate who's had his Tuono from new (2003).

Trying to add an image of my fuel leak evidence: