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Message started by lilmel on 04/26/10 at 17:16:57

Title: Gas cap leaking
Post by lilmel on 04/26/10 at 17:16:57

I tried not to fill it to the top but wanted a good full tank of gas for our trip .every time i rode it trickled out under the cap ,its a 2003 i have .i noticed that under the cap on th etank there really isnt much of a seal there.Dealer says i have to replace the whole thing 100 bucks with taxes later !!! i think i need to fix it myself lol.Also handle bars and foot pegs vibrate ...anyone have a quick fix?

Title: Re: Gas cap leaking
Post by verslagen1 on 04/26/10 at 17:29:21

Sure, tell the dealer he's an idiot, but doubt it'll do much good.

2 screws on the bottom of the cap and the bottom will come off.
the rubber gasket should be able to be pulled off now.
go out and buy a sheet of 1/8" or 4mm (not quite sure how thick, measure it and get the next bigger size) rubber and cut a gasket from it.

check your motor mounts 2 by the pegs and 3 on the head. loose mounts cause the motor to be loose and jump up and down more.

Title: Re: Gas cap leaking
Post by lilmel on 04/26/10 at 17:32:56

Thankyou i had bought a gasket but its to big i have to try and find out where to buy that sheet ,anyone in Ontario Canada and know where to buy it?

7C6F7879666B6D6F643B0A0 wrote:

Title: Re: Gas cap leaking
Post by verslagen1 on 04/26/10 at 17:36:07

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1250445664

Title: Re: Gas cap leaking
Post by babyhog on 04/26/10 at 18:37:58

Make your own... here's instructions.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1262920654

Title: Re: Gas cap leaking
Post by Boule’tard on 04/26/10 at 20:47:25

372433322D2026242F70410 wrote:

go out and buy a sheet of 1/8" or 4mm (not quite sure how thick, measure it and get the next bigger size) rubber and cut a gasket from it.

Yes, the ideal thickness is around 1/8" (3.2mm) to 4mm. That is thicker than the stock gasket, which is good.. you squeeze it down slightly with the cap and it makes a good seal.

It is pretty easy to fix the gas leak; no one should put up with it. For cripes's sake don't pay a dealer $100!! If you cannot find the right size "spud washer" you could get a sheet of gasket material and use the old gasket as a template and cut it out with an xacto knife or scissors.

Title: Re: Gas cap leaking
Post by Oldfeller on 04/27/10 at 03:03:30

Another fix used in the past was to add some cereal box paper cut to shim underneath the stock rubber washer to raise it up into a more positive engagement with the rim.

Use the existing washer as your pattern.

This is the "low cost" freebie fix ...

I think Justin first posted this fix about 3 years ago.

Title: Re: Gas cap leaking
Post by qp on 05/01/10 at 22:08:23

As gasoline is removed from the tank air needs to replace it. I have not noticed any tubing exposing the top of the tank to atmosphere, so it just occurred to me that the gas caps are designed to leak to allow air to enter. It seems like a stupid design idea but it would work. Perhaps air is supposed to enter the tank via the lock through the keyhole, but that seems to be stretching the reliability of an air path. Therefore, making the cap air tight would defeat that supposed design and allow a vacuum to be created as gas is drawn off, setting up a new set of problems. Any thoughts on this?

Title: Re: Gas cap leaking
Post by verslagen1 on 05/01/10 at 23:04:26

There are 2 one way vents built into the cap.
1 inhales, the other exhales.
California caps only inhales, as there's a vent tube built into the tank.

Title: Re: Gas cap leaking
Post by qp on 05/05/10 at 20:38:56

Hmm. I fixed my gasket so it sealed the tank, and wouldn't you know it, I starved my carb for fuel after about a mile. I opened the tank, closed it, and in another mile it simulated running out of fuel. Tried it a third time, same result. After I fixed the gasket so that the seal was not air-tight I have not had any problems. There are only 6000 miles on my bike, and if there are supposed to be vent holes they don't seem to be doing their job, and I doubt that the cap is defective, since when do caps break?

Title: Re: Gas cap leaking
Post by verslagen1 on 05/05/10 at 20:43:01

i'd take it apart and clean it, must be your salty air.
i haven't had one apart past the cylinder but it looks doable

Title: Re: Gas cap leaking
Post by qp on 05/24/10 at 16:46:38

The cap is clean, and it is not the salt. I installed several 1/8 gaskets I made myself so that there is a positive seal at the tank to prevent leaks. However, that seal also blocked the breather hole from under the lock. After much frustration I drilled a 1/16 hole through the top of the cap next to the breather hole. It is not elegant, but it is tiny and it will allow air to enter the tank as the gasoline is withdrawn.