Fuel Leak In A 1991 Key West 1900 Cc

[JVILLEJOE]

I have a 1991 Key West 1900 center console. Yesterday, when I put it in the water, it started and I was able to drive it around for a few minutes while my wife parked the truck and trailer.

Once we got on the water, the motor stalled and we had to be towed back to the dock.

We got the boat on the trailer, and when I removed the plug, liquid started to spill out, I noticed that it smelled very strongly of gasoline. I put my hand into the stream and it felt like gas as well.

I would guess that 4-5 gallons had spilled out.

I replaced the plug and towed the boat home. Once home, I emptied the rest of the liquid (into 5 gallon buckets) from the plug hole. I got about another 7-10 gallons of almost straight gasoline.

I put the liquid into the buckets to see if it was a mixture of water and fuel, and so far it appears that it is almost all fuel.

I believe that I have a 60 gallon fuel tank and prior to putting the boat on the water, I put 35 gallons of gas into it.

I put the gas into the proper fill hole. (someone already asked me of I was sure I didn't fill a rod holder) I know the tank was full because I stopped filling the tank when the nozzle shut off and when a small spray of fuel spilled out of the vent line.

Here are some other variables that may or may not have affected the situation.

When I first put the boat into the water, I did not attach the lanyard to the kill switch. It took me several times of trying to start the boat without success before I realized my error but the boat started up almost right away once I connected it.

When the boat shut off while under way, I checked the primer bulb and squeezed it a number of times to make sure I had good (pressure) in the bulb. The bulb is solid.

I believe that a solid bulb would indicate that the fuel pump is sending fuel from the tank to the motor. Because the bulb is solid , I also believe that there is not a leak in the line from the tank to the motor. I believe if there were a leak in the lines from the tank to the motor that the bulb would not get hard because air would be introduced into the sealed system and therefore not hold the pressure.

If the above holds true, then I would assume that the fill hose or vent hose is not properly connected. But if I filled the tank and it spewed out of the vent line then I would almost have to believe that they are connected properly and not leaking.

So I am only left to guess that there is a hole in the fuel tank and based upon the amount of fuel that leaked out, I can only guess that it is a sizeable hole.

It is possible that previous owners may have had issues with the fuel system because when I bought it, the fuel gauge did not and does not currently work.

I have a 2006 Yamaha 4 stroke 115hp motor on the boat and I have only owned it since 8-26-09.

Am I correct in making the assumptions regarding the primer bulb?
How about the fill line and vent line? Am I making the correct assumptions there?
Where and how should I begin to look for a hole in the tank?
Last question is why would the motor shut off and not restart if there were simply a hole in the tank.

I'm sorry I have been so wordy, but I felt that the more details I provided, the better shot of getting a good answer.

Can anyone help me figure this one out?

 

[scoutabout]

Re: Fuel Leak In A 1991 Key West 1900 Cc

Sorry to hear your day on the water was ruined. That's some interesting combo of issues you've got.

A couple of things I might try. If your bulb was solid, there is fuel getting to your induction system be it carbs or injection. Do you have a water-separating fuel filter installed? I'd also pull the engine cowl off and check the sight tube for water. There will be a red disk which is designed to float in that clear plastic fuel reservoir if you have water in your fuel.

I'd also yank and then reconnect your kill lanyard. Perhaps you didn't get it fully engaged and it moved a bit and killed your ignition again.

Sounds like there's an issue with your tank holding fuel, obviously. On the inside of your boat near your filler cap there might be an access port you can spin off to see the fuel hose connection. Ensure it's on tight at the deck end. There should also be another round access port in the cockpit floor somewhere that will give you access to your tank connections. (Unless I'm mistaken, there's no in tank pump. The fuel is sucked up by the engine). You should still be able to see if there's anything amiss in that area. Check your fuel line as far as you can trace it in either direction -- which may not be far. Much of your tank will probably be out of reach.

My point is, I'm not sure your fuel starvation issue (if that's it) is necessarily related to the leak. Suspicious though that the two would come so close together.

Are there any other panels under the deck you can open or remove to see the tank itself? And of course, no smoking or hot utility lights near the boat while you do this...

 

[Home Cookin']

Re: Fuel Leak In A 1991 Key West 1900 Cc

My 1988 Key West tank actually got a leak in it, down at the bottom. Slow leak, though.
Check these:
Fill line is loose or leaking near the tank.
Vent line is loose at the tank
fill line's entry joint at tank is broken
plate where fuel guage sensor enters is broken (they have been known to rust off)
supply line plate is broken, but supply pick-up is still in the tank.
(on all of the above, you can fill and operate with no apparent problem. The gasoline sloshes out, especially from a full tank, with operation of the boat, or when the boat is tilted while getting on a plane or being pulled onto a trailer.)
Supply line is loose or leaking--this would affect the "vaccuum" to the engine.

Be sure your battery is disconnected, the boat is stored outside and uncovered, and everything you can open is open.

 

[robert graham]

Re: Fuel Leak In A 1991 Key West 1900 Cc

My nephew up on the Nassau River has the same boat and motor, got water in that 60 gallon plastic built-in tank, had to remove t-top, center console, cut deck, remove tank, replace with new 40 gallon aluminum tank with drain pipe/valve/cap. He's still working on this boat but the water really played hell with the 115 Yamaha 4 stroke injectors, then all this tank business. Sounds like you may need a new tank, and I believe the installation is very important so not to have more problems. The pipe/valve/cap is stainless steel and drains to bilge, not transom, which I understand is forbidden by coastguard. It's always seemed to me that built-in tanks with no drains have to be just a big problem, especially with ethanol/water issues. Good Luck!

 

[JVILLEJOE]

Re: Fuel Leak In A 1991 Key West 1900 Cc

Hey folks, thanks for the resposnes. I looked under the cowling and thankfully it does not appear that there is any water in the fuel (the red ring is not floating).

As for the kill switch being stuck, I'll have to wait until I have a little more time to mess with things to try that out but it is a worthwhile option to explore. All of the other options that were mentioned are gonna have to wait until we get a little bit cooler weather and I can tinker without sweating like a stuck pig. It's been in the 90's and the humidity is 100%. I'll keep you posted.

I have noticed that the fuel in the bukets has seperated into fuel and a creamy looking mixture of what I think is water and contaminates.

My next question is or may be... Is it worth the expense of replacing the fuel tank in the event I have to go cutting up the deck?

The bluebook value of the hull is only about $1500.

I guess that will be a game day decision.

 

[scoutabout]

Re: Fuel Leak In A 1991 Key West 1900 Cc

...Is it worth the expense of replacing the fuel tank in the event I have to go cutting up the deck?

The bluebook value of the hull is only about $1500....

Ugh - no fun contemplating that I'm sure. You might make some calls to get estimates with and without the tank so you can roll the pros and cons around in your head awhile. I'm surprised the book value is so low for that hull. I'd have thought at least double that.

Depending on the problem you might need the tank or you could get lucky and discover it's a connection issue. I can see the dilemma though if you have it all opened. I'd want to be damn sure the old tank was in top shape before covering it over again.

Either way it's a nice motor and hull. I can't imagine getting yourself anything nicer even if it took a couple of Gs to remedy the problem.

Hopefully that's an absolute worst case scenario...

Another thing to consider in your troubleshooting is to get a fresh supply of gas to the motor by connecting another line and portable tank. Put the motor on the muffs and see if you can get it started on the the trailer. Don't do this though unless you can be sure your leak has stopped and you've got the bilge good and washed out.

 

[Home Cookin']

Re: Fuel Leak In A 1991 Key West 1900 Cc

I still think your leak has to be from the top of the tank and therefore most likely at a fitting.
My 1988 Key West DC has a removable deck over the tank. We still had to chop up the old tank to get it out and do some cutting inside the bow locker. The new one's design was improved to solve the removal problem and dropped in.
My view is that if you like the whole rig, it's worth it to replace the tank. If not, consider the cost to replace the whole rig and the fact that you can't sell the old one for much with a leaking gas tank--and with something that dangerous you should dosclose it. IOW is this repair the proverbial "last straw"?

 

[JVILLEJOE]

Re: Fuel Leak In A 1991 Key West 1900 Cc

Okay good news. (I think) I got to work on running down some of the fuel lines, and I figured out how to access the fuel tank.

I had to remove both batteries from under the center console.

After I did that, I found the factory screw off hatch. I also noticed that there was some type of a screwed down patch job right next to the factory screw on cover. Then I discovered that, if I can get the center console totally removed, that there is a lift off cover covering the fuel tank. (No sawing up the floor!!)

I also found out that I have an aluminum tank. (which I think is the best news). I also found that the patch job allowed me to easily access the in tank fuel sending unit. I found that the connections were pretty corroded, which I believe is the likely reason that the fuel gauge is not working. (another fortunate find)

By looking and feeling around, I located a worm clamp that is supposed to be securing a fuel line to the top of the tank. It was spinning freely around the hose. There is a "nipple" type connection protruding from the top of the tank that this line is very loosely connected to. Actually the line is barely on the nipple.

I am hoping and praying that this is my one and only problem. But the guy at the parts store really kinda scared me when he said I sholuld really get a pro to take a look at it. He said that if it isn't the only problem, then I could be sitting on a time bomb and never really know when it is going to go off ( He is right about that) so....

I called a friend of a friend (Doug) who works at a nearby tech school. Doug said to bring it by one afternoon and he would take a look at it.

What I would like to do is learn how to remove the center console completely. I suspect that all of the connections would have to have some type of connection avove the deck, so if I learn to make all the connections, then I should have most of the problems licked.

Even if I can't do it myself, I would like to remove the center console, replace the fuel fill line, the vent line and any other connections or lines available at the time. Then replace the sending unit with a new one and apply a corrosion retardant to the connections so it will last a while.

While the center console is off, maybe that would be a good time ot install a cheap marine grade AM/FM/CD player and a couple of speakers.

So any thoughts?

I hope that the one connection that I found is it, as far as leaks go, and I surmise, that because I filled the tank as full as I could get it, and with the boat in the stern down posture while stuck on the boat ramp trying to start the boat (with the kill switch unattached) then putting it back down the ramp (once I fugured out the kill switch problem) the bad fuel line connection allowed copious amounts of fuel to escape the tank.

Two days later, I am still having residual fuel leaking out of the drain plug hole.

I think that there are some baffles in the substraits of the boat that are retaining some of the fuel that appears to have totally flooded the underneath of the boat.

Luckily I am finding that gas evaporates pretty quickly.

 

[scoutabout]

Re: Fuel Leak In A 1991 Key West 1900 Cc

Sounds like you're making some good progress. If you get the chance post some pics along the way. I think it's an issue we can all relate to.

Remember when buttoning it up to use two good quality stainless steel fuel line clamps per junction. I believe that's the ABYC standard for marine fuel systems. I'm going to be adding a few extra clamps to my own boat.

 

[JVILLEJOE]

Re: Fuel Leak In A 1991 Key West 1900 Cc

I got brave and took the whole damn thing apart. It was a hole in the bottom of the tank!

It looks like the pervious owner had removed at least the top portion of the original plastic tank, then replaced it with an aluminum tank.

Once I removed the aluminum tank, I found a number of screws and lots of other debri under the tank. I am willing to bet that the scews had a huge role in the hole in the tank.

Lesson learned, don't drop screws and if you do, ya gotta go get them. You can pay now or you can pay later, but if you don't get them, you will pay!!

Now to see what it's gonna take to get it fixed or replaced....

 

[JVILLEJOE]

Re: Fuel Leak In A 1991 Key West 1900 Cc

I have some additional concerns now that I have figured out what my problem is:

The foam under the tank has become soaked in fuel. I know how dangerous gas fumes can be, so I am now scared to death that a buildup of fumes could cause an explosion. I am afraid that since the foam has been soaked, I will never be totally and 100% confident that there will not be a dangerous accumilation of fumes in the bilge/ hull area. 1) Should I consider installing some type of blower in the fuel compartment now?

2)Would a blower actually do what I want it to? That is expell any dangerous fumes and/or dry up the foam over time?

The previous owner only cut out the top of the old tank and left the remainder of the tank; installing the replacement tank in the shell of the old tank. 3) Should I leave the old tank in as well?

I have read that any water that comes into contact with an aluminum tank is not good and I believe that the lack of drainage in the shell of the old tank contributed to the corrosion and subsequent puncture of the replacement tank. 4) If I leave the old tank in, would I be better off in drilling drain holes in the old shell? I think that would do a good job of draining any water out without having to rip out the old one.

5) Which would be a better replacement tank? Plastic or aluminum?

6) Can an aluminum tank be reparied and/ or the hole patched with some type of epoxy?

 

[scoutabout]

Re: Fuel Leak In A 1991 Key West 1900 Cc

Good news you got to the bottom of it, so to speak. As for the remedy, I'm afraid there's no messing around with fuel leaks. I would advise removing all the soaked foam, get rid of the old half tank, clean out the hull completely and start fresh.

A blower is certainly designed to create some positive, fresh airflow through the bilge but unless you get the wet foam out you will never be able to completely relax.

As for what's the better material -- a couple of years ago I would have said plastic hands down but I've since been hearing that aluminum's bad rep for corrosion isn't entirely deserved. Do some research and see what you can find. I'd imagine plastic is cheaper but I don't know for sure.

 

[Home Cookin']

Re: Fuel Leak In A 1991 Key West 1900 Cc

forget the blower. I think you nkow you need to fix the real problem as scout says; a blower is a bandaid. And a blower motor could spark....

 

[JVILLEJOE]

Re: Fuel Leak In A 1991 Key West 1900 Cc

I have not been fair to all of the helpful folks who were so nice to offer their advice on what to do about my leak. I never responded when I solved the problem and for that I am sorry.

Here is what I wound up doing and what the problems were.

I found a hole in the bottom of my aluminum tank and decided after an attempt to fiberglass over the holes that I would be better off sending the boat to the manufacturer and having them fix the problem.

I took the boat to my local Key West dealer and they in turn took it to the Plant where Key West makes their boats in South Carolina. Once there, they cleaned the foam and bilge area with a solution that removed all of the fuel and fuel odors.

I then installed a new plastic 40 gal tank where the original 60 gal tank once was.

According to the manufacturer, with the 4 stroke motor on the boat I should get the same mileage as I would with a 60 gal tank and a 2 stroke motor.

Once the boat was home, I took it for a sea trial, it would not get on plane properly, and after a lot of trial and error, I found that the fuel injectors were to blame.

My local Key West dealer wanted $100 a piece to clean them. Fortunately I found a California firm that would do all 4 for $100.

Once I got them back from Calif. I still had some issues, I took it to the Key West dealer and he was able to figure out that upon reinstalling them, I bent a connector and they were able to straighten it out and get it running.

So, the boat is working like a champ. I am learning a lot about how to care for a boat, since it seems that every trip is an adventure and something else goes wrong, but I have learned to take these adventures in stride.

I am a very happy boat owner and I have learned tons about what I do and don't want in a boat.