1993 K75 fuel level float o-ring

[sci]

Hello guys,
I have a 1993 K75 and developed a leak from under the fuel tank. I’m 99.9% it is the fuel level float o-ring and I have ordered a new one. My question is; I can cut the old one out but the new one will never stretch over the base of the float assembly. Has anyone replaced this o-ring and how did you do it?
Thank you,
-Dan

[The Mighty Gryphon]

Hmmmmm...  I have replaced a couple of those o-rings, and now that you ask, I can't recall how I did it.  I do know that it wasn't difficult.  I think it went over the float and the sender, but can't say for sure. 

[Martin]

Empty and remove the tank. Remove the fuel filler cap assembly. Disconnect the wiring to the fuel pump. Remove the four Phillip's head mounting screws, be careful not to strip the heads. Once the screws are removed with a bit of wangling the sender unit can be removed. It helps to observe with a torch which way you have to orientate the sender as you remove it. Remove the old "O" ring and fit the new one making sure as you reassemble it that the "O" ring is properly seated. A small dab of silicone grease can help keeping it in place. Tighten the screws evenly.
Regards Martin.

[frankenduck]

Empty and remove the tank. Remove the fuel filler cap assembly. Disconnect the wiring to the fuel pump. Remove the four Phillip's head mounting screws, be careful not to strip the heads. Once the screws are removed with a bit of wangling the sender unit can be removed. It helps to observe with a torch which way you have to orientate the sender as you remove it. Remove the old "O" ring and fit the new one making sure as you reassemble it that the "O" ring is properly seated. A small dab of silicone grease can help keeping it in place. Tighten the screws evenly.
Regards Martin.

In the US we call a flashlight a flashlight, not a torch. A torch is something that spews fire.

[Martin]

And, what's wrong with spewing fire???? And I also refuse unconditionally to speak or spell American.
Regards Martin.

[daveson]

In other words, and a shaky memory, remove the sender, place the o-ring in its location on the outside of the tank, then replace the sender. Therefore it doesn't have to be stretched over the base.

With the tank upside down on something soft to protect the paint, if you feel any resistance when installing the sender, stop. Look to make sure the float isn't on the wrong side of the drain pipes or other obstructions. Make sure the o-ring contact surfaces are clean and smooth.

[sci]

Thanks Gryphon, frankenduck and daveson. I got hi-centered at work yesterday. Martin, I knew exactly what you meant and love the irony. Keep up with that accent. I enjoyed it.
-Dan