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411 Fuel level sender seal leak/blowout

SilverCycle

Well travelled
Just interested to see if common, or other explanations.

Yesterday, we picked up our two Him 411s after a major service (so tank off), at an RE service centre that we know sees plenty of 411s. We had dropped the bikes off with almost empty tanks.

Today we set off, filled up, and rode ~60 warm, tortuous, but smooth km. Stopped for a break, after which Clare exclaimed - my Him's leaking petrol all over the floor. And it was. Dribbling off the throttle body and all over to the floor. That's with key out. And it sat there 30-40 minutes doing it.

Problem turned out to be leaking seal where the fuel gauge sender is bolted into the bottom of the tank.

Right after a service.

So, I reckon the tank had been put on pinching the evap pipe, and it had overpressured the tank and burst the seal (o ring).

Any other theories? That sender is deep in the crotch of the tank, hard to damage by accidentally whacking? It was me who, in the repair, disconnected the fuel line, evap & overflow, so I know they were put back on after the service.

Is it common?
 
Oh dear. But it seems so improbable that it would be damaged by a blow or something. Still, only my theory. Wasn't a minor leak, either, even once depressurised. I didn't mention above that as soon as I saw the leak I popped the filler open, in case it was pressure - it didn't stop the flow.

Really I'd have though that in an overpressure scenario it ought to vent at the filler cap, since it's the top. Or blow the evap hose off (hard for user to observe, though).

It was an impressive piece of origami watching the guy thread the float arm back in. If I ever take one out, I think I will video the route!
 
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