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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Leaking Gas Cap /cgi-bin/YaBB.pl?num=1273178625 Message started by michelleb318 on 05/06/10 at 13:43:45 |
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Title: Leaking Gas Cap Post by michelleb318 on 05/06/10 at 13:43:45 Has anyone here had a problem with gas leaking out the sides of their gas cap? My 2007 Suzuki Boulevard LS650 (or S40) started doing that a few months ago. I thought I was just overfilling the tank when I gassed up ... but it did it even when I filled it up only about halfway or so. Two weeks ago I brought it to the local dealer who, for some reason, couldn't even get the cap to come off. They ended up removing the tank, emptying it out (I'd just filled it up the night before) and drilling the cap out. Then it took them nine days to get a replacement cap because I have an extended warranty and they went through Suzuki California. I would gladly have paid extra to have the cap overnighted, but they never told me where it was coming from. They knew I was going on a ride with about 100 other bikes the next weekend (9 days later) but the bike wasn't ready until late in the afternoon of the ride ... and I was already ON the ride, as a passenger. Well, I picked my Thumper up Tuesday night and now I have TWO problems. First of all, they apparently damaged the tank so they had it repainted - and it doesn't match the rest of the bike. (My bike is the white/pearl color.) Plus, I sloshed the tank around a bit and guess what? Gas came pouring out around the new gas cap. So ... 12 days after I dropped it off, I still had the exact same problem. I was so angry with the dealer that I contacted Suzuki ... and apparently they chewed the dealer out. Now the dealer says they will get me a new tank and gas cap ... but if I have to wait almost two weeks AGAIN, I will FLIP out. As it is, I will never go to that dealer again ... if I get another bike it will NOT be from them. So ... back to my original question - has anyone else experienced gas leaking out under their gas cap? And is there some sort gasket on the lip of the tank that maybe mine is missing? Thanks, ~Michelle |
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Title: Re: Leaking Gas Cap Post by prechermike on 05/06/10 at 13:48:57 Hey Michelle, Not a happy start, I must say, but welcome aboard anyway. There is a search fearture, that is a little tricky to use, but it works pretty good. There seems to be a rash of leaking gas caps all of a sudden. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1272327417 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1250445664 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1262920654 Have Fun! |
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Title: Re: Leaking Gas Cap Post by michelleb318 on 05/06/10 at 14:16:43 Thanks ... believe it or not, I read all three of those before you replied to me! LOL!! Seems like the problem is more common than I thought. At least I don't feel like it's just ME! ~Michelle |
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Title: Re: Leaking Gas Cap Post by bill67 on 05/06/10 at 15:03:15 I don't believe its that common to newer bikes,I've had a lot of bikes and never had a single one leak,Maybe some older bikes that have been left outside were they go through the cold and hot weather could leak,My bikes have always been kept in a garage.But you really must have a bad dealer,Why would they take off the gas tank because the gas caps leaks.The gasket is on the cap only.Do you have the arrow facing forward when you put the cap on. |
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Title: Re: Leaking Gas Cap Post by Charon on 05/06/10 at 15:16:16 My '07 S40 started a gas cap leak last year. If I fill it to the filler neck in the tank and put the cap back on, then as I ride away a little gas comes out around the gas cap. If I fill it to the neck, stand the motorcycle upright and "burp" the tank, then put the gas cap on it seems to be OK. I'd be interested to know whether the California bikes with the charcoal cannister and the vent tube do the same thing, or whether it is a 49-State vented gas cap problem. My bike is kept in a garage during the summer, and in a shed during winter. Neither building is heated, but the bike is protected from sun and wind. I point out that in general, motor vehicles including motorcycles are considered to be outdoor devices, and as such should be designed to withstand the weather. |
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Title: Re: Leaking Gas Cap Post by bill67 on 05/06/10 at 15:21:56 I've never heard of burbing a gas tank til I got here and don't do it.I must fill my petty full because I normally go 135 mile before I have to go to reserve. |
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Title: Re: Leaking Gas Cap Post by Charon on 05/06/10 at 15:30:13 I couldn't think of any better terminology than "burping". I fill the tank to the filler neck, generally trying to fill the tank so that part of the slanted filler neck is in the gas and part is out. I then slowly stand the bike upright, and usually as it comes upright the fuel rises in the neck, followed by a good-sized bubble which allows the fuel to drop a bit. My guess as to the cause of the leak is that the bubble can't escape quickly enough through the gas cap vent, so it pushes some fuel out either through the vent or past the gasket. I think past the gasket is more likely, since the gasket may have compressed a little with age and may not be sealing as well as when the bike and gasket were new. Gee - I wonder if Seafoam would cure it? |
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Title: Re: Leaking Gas Cap Post by bill67 on 05/06/10 at 18:30:52 Sea Foam will keep the gasket from drying out. |
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Title: Re: Leaking Gas Cap Post by justin_o_guy2 on 05/07/10 at 03:07:22 I took my cap apart & cut & installed a shim to put under the rubber to make it sealo better. Its a bit of a hassle , gotta push down to twist the key, but it doesnt leak like it did. |
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Title: Re: Leaking Gas Cap Post by michelleb318 on 05/07/10 at 06:02:43 We LOVE Seafoam ... but it didn't help with my cap. :( |
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Title: Re: Leaking Gas Cap Post by Charon on 05/08/10 at 05:44:38 Come to think of it, neither of my Kawasakis have the problem (so far). But on both Kawasakis the gas cap is centered on the tank, so when the bike is raised from the sidestand the level of fuel in the center doesn't change much. The S40 cap is on the right, and when the bike is raised from its left-leaned sidestand position the fuel level on the right side of the tank rises. The S40 is known to have a few design issues, and perhaps this is just another of them. |
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Title: Re: Leaking Gas Cap Post by justin_o_guy2 on 05/08/10 at 07:32:10 Charon says.. The S40 is known to have a few design issues. Heretic! Stone him! |
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Title: Re: Leaking Gas Cap Post by wingsout on 05/08/10 at 08:23:03 Mine leaks too.(05 S40, 12,000 miles). |
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Title: Re: Leaking Gas Cap Post by Charon on 05/08/10 at 10:27:52 Let him who is without aim cast the first stone. |
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Title: Re: Leaking Gas Cap Post by verslagen1 on 05/08/10 at 10:43:06 7E555C4F52533D0 wrote:
roflmao [smiley=2vrolijk_08.gif] |
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Title: Re: Leaking Gas Cap Post by EJID on 05/11/10 at 16:14:23 I stay on my bike while filling it up and keep it vertical. I've never had an issue with a leaky gas cap either. |
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Title: Re: Leaking Gas Cap Post by bill67 on 05/11/10 at 17:00:06 I have never stayed on my bike to fill up,Alway put it on the kick stand,Never had a gas cap leak or burped the tank,Which is new to me I never heard of it til I got here. |
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Title: Re: Leaking Gas Cap Post by Charon on 05/11/10 at 17:29:02 Personally, I think it is unwise to sit on the bike while refuelling. You are sitting on a machine with a hot engine and exhaust. It is easy to overfill the tank, or spill a little fuel when removing the nozzle. Spilled fuel can easily run down the tank to your crotch, where at the very least it will be uncomfortable. Anyone who uses a Zippo lighter and has had the fuel run out onto their leg can relate. At worst there is the slight possibility of fire. There is a fair chance you will need to get off the bike to go use the restroom, anyway. And all hazards aside, I usually find it feels good to get off the bike and stretch. |
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Title: Re: Leaking Gas Cap - Update! Post by michelleb318 on 05/14/10 at 04:32:47 Hey, everybody - I just thought I'd give you an update on my gas cap issue. Suzuki chewed my dealer out pretty well ... apparently the dealer never contacted Suzuki at all about the gas cap issue. To make nice-nice with me <g> Suzuki sent a brand new gas tank and cap to my dealer. I dropped the bike off after work on Wednesday and picked it up after work on Thursday. (1 day instead of 12!!) Well, now the bike looks practically mint! Suzuki did forget the nice Boulevard stickers that go on the sides of the tank, but they're now on the way too. So ... those of you with leaky gas caps might want to contact Suzuki directly. I did have an extended warranty on my bike but you never know, they might just replace your tank & cap for free too. BTW, when I had to sign the warranty paperwork, I saw the price of the gas tank - $544 !!!! Holy moley - I'm glad I didn't have to pay for it!!! Here's the website: http://www.suzukicycles.com/ From the website: "Should you have a situation that you believe requires American Suzuki's immediate assistance you may call Customer Service at 714-572-1490. Customer service representatives are available from 8:30AM to 5 PM PST." and I spoke to Cecil. BTW, DON'T tell him I sent you - LOL!! ~Michelle |
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Title: Re: Leaking Gas Cap Post by bill67 on 05/14/10 at 04:51:58 That was nice I don't think that happens very often. |
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Title: Re: Leaking Gas Cap - Update! Post by michelleb318 on 05/14/10 at 05:39:18 I think I lucked out for two reasons: First, Suzuki was never contacted by my dealer about the gas cap and it was NOT ordered from them. (I think it was an after-market cap.) That meant the dealer lied to me about the cap coming from Suzuki in California and used them as an excuse for it taking so long to arrive. Suzuki was not pleased about being bypassed for the cap. Second, Suzuki was NOT happy about an upset and irate customer who, 12 days after it was dropped off with the leaky cap issue, now had a bike with a mis-matched tank and a cap that still leaked! If YOU were Suzuki, would you want one of your licensed dealers giving such poor customer service and repairs? Now that I've thought about it, I think the dealer took that long because they were waiting for the paint job to cure on the tank. It didn't cure - after my first short ride after picking it up, the tank had scratches and pock marks in the paint. (Let me just say that after 4500 miles and eight months of riding, the original tank was still mint.) So ... I'm pretty sure they had it painted over the original paint, rather than stripping it down to the metal. The good news is that it's supposed to be nice tomorrow and I'll be taking my Thumper out for a nice long ride. Woo- hoooooo!!! 8-) ~Michelle |
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Title: Re: Leaking Gas Cap Post by michelleb318 on 05/14/10 at 05:44:58 Hi, Bill67 - Well, my bike is a 2007, so I think that's pretty new, isn't it? The dealer took off the tank because they damaged it when they were trying to remove the cap. Yes, the cap had the arrow facing forward ! I don't really know what happened to make it not come off - it was fine when I filled the bike up the night before! They ended up drilling the cap out, and apparently damaged the tank when they did so. Luckily all is well now and my bike looks great! ~Michelle 555E5B5B0100370 wrote:
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Title: Re: Leaking Gas Cap Post by michelleb318 on 05/14/10 at 06:01:49 517A73607D7C120 wrote:
I agree, Charon. I always have my bike on the stand when I fuel up. Two weekends ago I witnessed a Yamaha Roadstar Silverado 1700 bursting into flames just 10' from the gas pumps where it had just been gassed up. Yamahas apparently have carb float issues and that's why the owners manual says to shut off the fuel valve whenever the bike is not running. (We don't have that problem OR an off valve with our Thumpers!) This Yamaha had been shut off and was sitting for at least 10 minutes before being gassed up and rolled away from the pumps. I wasn't back on it until it was away from the pumps so the next guy could gas up. (I was on a 175 mile run with about 100 other bikes - it was a beautiful day!) It was probably another 10 or 15 minutes before I got back on it and the rider attempted to start it. (I would have been on my own bike if it wasn't still in the shop with the gas cap mess....) Let me just say that it was pretty scary - I hopped off the back of that bike pretty darn fast when someone yelled FIRE right next to me!! Luckily there was a volunteer fireman standing outside the Stewart's store who ran in, got a fire extinguisher and put the bike out. The only damage was to the air filter box, a bit of wiring (not destroyed) and a bit of melting over the carb. That claim is going in to Yamaha as we speak. BTW, after the firetruck hosed the chemicals off the bike (3 trucks and 2 police cars responded!!!), it started right up and we continued the last leg of the ride! The funniest thing about it was the identical Yamaha next to us at the pumps. He was afraid to start his bike. When we all got moving again, he was right in front of us ... and kept looking down to make sure he wasn't on fire. We laughed ourselves silly the last 20 miles of the ride. LOL!! Anyway ... it would seem I have an affinity for gas tanks and fire .... lucky me!! ~Michelle |
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Title: Re: Leaking Gas Cap Post by jef.savage on 05/14/10 at 13:22:00 I'm glad it worked out for you. Some folks put a lot of effort into removing those tank badges for a cleaner look. Maybe just get them from the dealer and hang onto them in case you decide you miss them. |
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Title: Re: Leaking Gas Cap Post by rjackb on 07/14/12 at 18:50:45 332C2A2D30370636063E2C206B590 wrote:
Can you describe this a bit more? I just replaced the gasket on my '07 but it still leaks if I fill it up to the neck. I was trying to think of a way to make the gasket thicker and you seem to have found one. |
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Title: Re: Leaking Gas Cap Post by justin_o_guy2 on 07/15/12 at 06:06:55 I did that about 5 or 6 years ago,, All I remember for sure is taking the guts out of the cap & getting that rubber gasket in my hand & cutting a piece of plastic to put under it, It made it fit tighter, for sure, Something to look at is the top of the filler opening, where the gasket is supposed to seal,I took a sanding block & smoothed mine up a bit, it wasnt as even of a surface as I thot it needed to be, Remember to push down on the cap so the key isnt trying to drag the locking pins in as they drag against the tank, & test the cap to make sure its all working before ya slap it on, I cant even put mine on w/o turnin the key,, I might Could, but I dont like forcing things. |
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Title: Re: Leaking Gas Cap Post by rjackb on 07/15/12 at 18:53:39 Thanks. I'll try adding some depth to the gasket somehow. I'll also try smoothing out the lip of the filler hole since it does appear to be a bit irregular. Mind if I ask how you kept your sanding from entering the gas tank? |
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Title: Re: Leaking Gas Cap Post by justin_o_guy2 on 07/15/12 at 22:09:56 I cant remember, but if I was gonna do it today, I guess Id run the gas low & stuff a rag in thereso it would catch & hold the stuff,, not just crammed in there, so It came out with the crud in it, minimize it by running the sanding block from the holoe out. |
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Title: Re: Leaking Gas Cap Post by arteacher on 07/16/12 at 10:27:17 What I did was: drain the tank and stuffed an oily rag in it, then masked off the opening (there is enough of a lip there to get the tape to stick), then sanded it with emery cloth on a sanding block, then wet sanded with two more grades of sandpaper. I vacuumed the residual grit off the tape, pulled the tape, and then the rag. The purpose of the rag was to catch any crap that might have got buy the tape. |
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Title: Re: Leaking Gas Cap Post by rjackb on 07/16/12 at 18:20:53 I actually was thinking of the "stuff a rag or something in there" approach so thanks for validating that. I'm mechanically oriented so I don't think it will be a problem. Thanks again. |
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Title: Re: Leaking Gas Cap Post by tizzyfit on 07/19/12 at 08:37:53 Heretic! Stone him![/quote] Do you have to soak the stone is Sea-foam before launching it? ;D |
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Title: Re: Leaking Gas Cap - Update! Post by justin_o_guy2 on 07/20/12 at 09:31:04 787C767D707979707726242D150 wrote:
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Title: Re: Leaking Gas Cap Post by rjackb on 07/20/12 at 21:40:59 Replacing my gas tank gasket with a new Honda gasket was a big mistake. I get even more overflow from my tank than with the original Suzuki gasket that was so hard that I can't even see how it could have possibly worked. I will definitely be thickening my gasket somehow as well as smoothing out the tank lip because this overflow is completely unacceptable. |
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Title: Re: Leaking Gas Cap - Update! Post by RpNSht on 07/23/12 at 16:37:25 so despite my best efforts my gas cap still leaks. i have replaced the gasket with a different gasket but i havent done the washer under the gasket trick. instead i took michelle's lead and gave cecil a call. after a few minutes we realized that one cannot purchase the gasket on its own nor does suzuki offer a part number for this piece. so, i filled a complaint and i told cecil that i was going to have all my fellow savage owners call him up to file complaints as well. please call cecil and file a complaint. maybe we can get something done about these faulty caps! call cecil in Customer Service at 714-572-1490. Customer service representatives are available from 8:30AM to 5 PM PST. 24202A212C25252C2B7A7871490 wrote:
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Title: Re: Leaking Gas Cap Post by justin_o_guy2 on 07/23/12 at 22:54:39 I cant just poke my key in & turn it, well,, I MITE could, but it wouldnt be easy & Im afraid Id break the key off,, Can YOU just turn the key on your leaky cap? If so, there just may not be enough pressure on the gasket to seal it off, Have you inspected the lip on the tank? Is it flat? A piece of glass, a little oil on the tank lip,, otta show if its got a problem spot, |
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