Leaky & wont start. Bandit 1200, 2002

[Ericchino3]

 Just had Petcock rebuilt yesterday on my Bandit 1200, "02" to fix gas leak.  Awoke to gas leaking from tube connected to small filter box under seat.   Took bike back to shop this morn & bike wasnt leaking at all. Mechanic recommended to install Carb Rebuid kit if it happens again.

Now bike wont start,  gauges move but but dont light up.  Nothing happens when I turn ignition.  A few times I thought I heard a clicking sound when pushing starter buton.

Any ideas if its battery, starter, connection, hydro locked  or gas leak causing start problem?

[ventYl]

if yo had gas leak condition, try to remove spark plugs so you know if it is hydro locked or not. i don't see any reason for starter not being working after carb rebuild.

hydro lock is quite believable scenario here

[Ericchino3]

Thanks but I only replaced Petcock so far.  Carb rebuild kit is my next move if I can figure out start up problem.  I will try plugs also as you recommend. 

[Ericchino3]

I believe I found start problem!   Broken left battery attachment.  Corroded left battery bracket.  Any brand recommendations for a new battery?

Also do you think bike will start even with leaky gas issue?   

[Ericchino3]

4th VISIT TO MECHANIC FOR THIS ISSUE & THEY'ARE STILL NOT SURE HOW TO FIX.  AAARRRGH! 
 
My bike still leaks gas sometimes from a tube connected to black filter box under battery area. 
Mechanic now recommends rebuilding carbs after changing plugs, new petcock, cleaning fuel lines, water removal & new battery.
 
Bike still struggles to start up.  Tapped on float bowls, adjusted Idle screw to help with bike cutting off when idling. 

Bike still not running well,  almost feels like it's not firing on all 4 cylinders.  Usually feel heat coming off lower left shifter area but not now when I ride bike. 

Planning to check & or change my new 25 day old plugs also.  Ordered a Carb Rebuild today but hope it might be an adjustment or something requiring less labor. 

Does anyone have any feedback besides change my mechanic?   Lol

[ventYl]

as a very quick way to tell if your problems are caused by leaking carbs:

dunno if B12 mikuni's do have them but B4 mikuni's have small noses in place of float bowl drain line so I am able to connect transparent tube (3 or 4mm inner diameter?) to them. This way you can attach one tube to each carb, put bike upgright on centerstand, attach other ends of tubes somewhere above the carbs level and open all drain screws. If fuel levels in all four tubes will be equal (+-1mm) even after some amount of time you can try to crank it up to. While you have your petcock rebuilt I don't think it will leak when not running but it might leak when running or short time after it is shut down.

If some fuel level will vary from others or during the time then your carbs are most probably eligible for rebuild. Carb rebuild is not very labor intensive. After you do it five dozen times you'll be able to replace all O-rings in under half an hour. :) Just be careful to not lose anything or break some of new O-rings.

edit: Good news is that your spark plugs are most probably not dead (if no cracks are visible on insulator).

[Ericchino3]

Awesome, thanks.   Very interesting,  I will ask mechanic to try that.   If not labor intensive why is shop quoting me 3.5 hours to rebuild carbs then? 

Starting to think shop is just troubleshooting :(

[ventYl]

Well shop will eventually tear them completely down and clean them properly (as a precaution for the case that some dirt forgot inside will ruin all the work). Another point is that it might not be that easy to get the carb rack out of B12 frame. I don't have an experience with B12 with new frame type (straight tube under the tank) but removing carb rack out of 1st gen B6 was plain PITA.

edit: train train train and you'll be able to remove carb rack, replace O-ring and mount rack back in time shorter than typical ad block on tv :D

[Ericchino3]

After carb rebuild, new petcock, filters & plugs bike is leaking again from a tube connected to a lil black box under seat which I think might be a filter box.  I'm about to bury this bike :(

[ventYl]

where is the other end of the tube connected to? cylinder head cover? or free mounted to frame?

Former one is crankcase breather tube and it is more/less normal that some gas vapours are condensing out of this (especially if you didn't change oil after leak or you are often doing a cold start with choke).

Latter one is airbox drain tube. There should be foam element inside preventing suction of air through it but allowing any liquid present in airbox to drain out. If liquid draining out of this tube is gasoline (it might be oil condensate from crankcase breather tube or water catched there) then there's question where did it came from.

You might still have some carb problems (either leaking O-ring or stuck needle).