SuzukiSavage.com - Fuel cap

911radioman

Ex Member

Fuel cap
02/10/06 at 14:23:25

I did a search before posting this, didn't seem to find what I was looking for so pardon me if I missed it somehow!

I'm noticing some gas leaking out around the fuel cap and running down the tank. I checked the cap to make sure it was seated and locked securely - it is.

Question -- is there an issue with these fuel caps I need to be aware of? Does the gasket need replaced on it or should I just spring for a new cap?

Any help will sure be appreciated!

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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Fuel cap Reply #1 - 02/10/06 at 14:45:54 i dont think u can buy a new seal,i tryed to at a local gasket shop,but the stock gasket has a metal backing on it to make it stiffer. i mixed up some clear coat and heavily applied it around the filler tube... it made the seal fit super tight. keep in mind that the gas tank vents through the gas cap.
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thumperclone Serious Thumper Alliance Member Offline PGR rider riding with respect Posts: 5867 Grand Junction Colorado Gender:	Re: Fuel cap Reply #2 - 02/10/06 at 14:46:34 ive had my s40 for about ten days now. on my first fuel up i filled up with the bike on the side stand..when i leveled it back up gas came out from under the the cap.now i sit on the bike and hold it level while fueling..only to the bottom of the neck!!i would think the cap needs to breath for fuel to flow..hope this helps.
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911radioman Ex Member	Re: Fuel cap Reply #3 - 02/10/06 at 14:55:16 I can understand the venting part of it, but it bothers me that gas would make its way out. I don't want to have to repaint the tank because the gas eats it off. Don't want to have to buy another cap either, those suckers are $55.00!!!
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SeeAPierce Senior Member 2005 No Login Offline Posts: 282 California Gender:	Re: Fuel cap Reply #4 - 02/10/06 at 15:22:00 yea - like thumperclone notes, make sure you're only filling to the bottom of the filler tube, with the bike standing upright...shouldn't leak then... What year is the bike? Is there damage to the paint now that makes it look like it's been leaking before you got it?
Back to top	'06 S40 green: sporty muff & 10 degree adapter 155 main jet, 1/2 white spacer, open filter, bar end turn signals IP Logged

911radioman Ex Member	Re: Fuel cap Reply #5 - 02/10/06 at 16:04:26 It's an '02. There is nothing there on the paint to indicate that this was a problem before, so it may just be me and not used to the way this bike needs to be filled with gas.
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Reelthing

Serious Thumper
Alliance Member

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Fish or ride that is
the question

Posts: 5397
Houston,Tx
Gender: male

Re: Fuel cap
Reply #6 - 02/10/06 at 17:01:11

so do these leaks only happen after a fill up ?- if so what i do after a fill up on the side stand is stand the bike up right before I put the cap on - maybe even rock it back and forth a few times - there is an air pocket that forms in the upper left top of the tank you need to equalize - or the '95 will leak quite a bit - the '02 doesn't but it's a newer gasket.

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911radioman Ex Member	Re: Fuel cap Reply #7 - 02/10/06 at 17:02:22 It's the only time I've noticed it thus far. Of course, I just picked the bike up yesterday so I'm still learning its little quirks.
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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	Re: Fuel cap Reply #8 - 02/10/06 at 17:04:33 yeah, that's what it is, just takes some time figure her out
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necropsy Full Member 2005 No Login Offline Suzuki '05 S40 Posts: 173 Barrie, Ontario, Canada Gender:	Re: Fuel cap Reply #9 - 02/10/06 at 17:49:46 I bought a 05 s40 last fall........... Gas cap leaked from day one, front brakes squeak like crazy, and the speedo housing rattles, First rideable day, she's going in for some warranty work.
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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Fuel cap Reply #10 - 02/11/06 at 22:34:39 I've only had a leak on overfill (past than the bottom of the filler tube).
Back to top	1998\|MAC muffler\|ceramic coated header\|K&N air filter\|Amal Mk2 carb\|Odyssey battery\|iridium plug\|NC windshield\|Dunlop 491s\|Superbrace\|EBC brake rotor\|12.5" Progressive shocks\|Kuryakyn ISO grips IP Logged

911radioman Ex Member	Re: Fuel cap Reply #11 - 02/16/06 at 16:45:01 I've noticed a rattle in my headlight housing, probably didn't get something quite placed right when I upgraded my stock headlight to the xenon bulb. I've been trying to watch when I fuel up now so as to try and avoid the leaky fuel cap. So far, so good on that one...
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SirWilhelm

Ex Member

Re: Fuel cap
Reply #12 - 02/16/06 at 18:25:31

I just did the new shocks upgrade on my '05 S40 and went by to fill up. I did the "lean it on the kickstand to fill", and only filled to the bottom of filler tube. And put cap on rolled bike up straight and gas poured out from under the cap. AARRGGHH. I could see my self setting the whole station on fire as it ran down on the engine.
Luckily it just evaporated. Seems that with the new angle of the bike due to height rise with 11.5 shocks, the tank has a lot of room you don't find when upright.
So I too will only fill up with the bike straight up in the future.
Did find a real hockey puck at sports store and will glue it to bottom of the kick stand this weekend to see if that will raise the bike more vertical. Hockey puck looks better than some of the bolts, and home made blocks I have seen. Need some liquid weld and it should do well. I got one from the Dallas Stars, but they had them from all over. The street hockey ones are just hollow rubber, so no use.
I don't like spilling gas, and especially when a lot runs onto the engine. Now I need to take the bike and spray wash it real good.
Oh well, time to clean it anyway, for the first 1000 mile cleaning.
Hey we don't get rain, so you don't wash your vehicle out here, as it just gets more dust on it!

Bill

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