Question about 1993 Harley Davidson XLH Sportster 883

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Got JB weld or braising in my fuel breather

Previous owner redid the fuel tank on my harley and plugged the fuel breather with JB weld or Braising. Now the bike gets vapor lock. any ideas on how to get it out without making a spark and going KABOOM?

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  • Jessie Lamison Jan 22, 2009

    I have no idea why they blocked the breather. But i got to get it out. Im just worried about drilling cuz it only takes a little bit of fumes to make a big BOOM.

  • Jessie Lamison Jan 23, 2009

    Hey thanks for all your help


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Take tank off empty gas . rinse out tank . fill with water . this is how i weld holes in tanks

Posted on Jan 31, 2009

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Remove the fuel tank leave the cap off and get a small drill bit and re drill the hole using a hand brace or a nut driver. if your careful you can use a battery powered drill or electric drill. why did they cover the breather hole?

Posted on Jan 22, 2009

  • ga_drifter
    ga_drifter Jan 23, 2009

    well you could let it air out for a few days after you drain it, but wit this cold snap of weather we are having gas fumes arent as bad in cold weather. you could try filling the tank with water while drilling but be sure to wash out with fresh gas immediatelt after drilling and removing the water. but be real careful and you wont have to use the water solution. just be careful and keep a fire extinguisher handy. usually you will only have problems around open flame such as a cutting torch.


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Hi, Shawn it is rare but it does happen the diaphragm in your fuel valve/petcock has failed and allowed gas to flow through the vacuum line into your cylinders and into your bottom end where it gets pumped back into your oil tank and once the oil tank gets overfilled it pukes out of the breather right into you air cleaner which you will need to replace as it is no oil soaked. Repair the fuel valve with a kit from Harley or aftermarket or buy a new fuel valve not vacuum operated, you will have to plug your vacuum line if you go this route, drain all your oil leave the drain plug off start the engine let it run until the low oil pressure light comes on to completely drain the oil system, shut the bike off and replace the drain plug and replace oil and filter. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below, and for specific information or questions please feel free to contact me at Good luck and have nice a day.
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Hard starting kicks back spits oil out breather but always starts and run good after starting

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If you need a replacement tank, the easiest but most expensive source for a replacement tank would be to check with a Yamaha dealer. Yamaha may have a NOS tank in stock, but the dealer may also have a private boneyard. More likely, your best bet is to look for a motorcycle salvage yard. If a yard doesn't have the part, they can put out a search of other yards and get it that way. Your local yellow pages may have a listing for motorcycle salvage yards, but you can also run a Google search for "motorcycle salvage yards" and go the mail-order route. The first hit I clicked,, had a variety of Yamaha gas tanks starting at $50, plus shipping. Of course, you can also check eBay, where I've had good success finding oddball motorcycle parts that many salvage yards don't keep in active inventory anymore.

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What could cause excessive oil pressure in the oil tank of an 1988 evo, plug blows out of oil tank, when loose plug is left in oil weeps from tank and caskets have started to leak. I have changed the...

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