SuzukiSavage.com - Fuel flowing out onto the tank from cap

KenGLong

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2002 Savage

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Albuquerque, NM
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Fuel flowing out onto the tank from cap
07/30/09 at 14:48:59

When I got my '02 running again, I had massive amounts of gasoline flowing out from under the gas cap after a fill up. I'm not new to the Savage and I know that you have to stop filling it when the level reaches the bottom of the filler neck. I was doing that and it was still flowing out.

I checked the price for a new cap, since you can't get just the gasket, and decided that I wasn't going to pay $52 for a darn gas cap even if it's gold plated. I dug around in the garage and found a package of bulk gasket material. I cut out a piece of 1/8" cork so that it would fit into the cap under the existing rubber gasket. On my next fill up, I deliberately over-filled it a little just to see what would happen. I put the cap back on, got on the bike, pulled it upright and waited for it to start leaking. No leak. I then took off down the road, went around a couple corners and it still didn't leak.

Saved $52.

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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	Re: Fuel flowing out onto the tank from cap Reply #1 - 07/30/09 at 19:22:03 It's sometimes helpful on these tanks to rock them back and forth a little before you cap it up to burp the air out of the far corners
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Starlifter Serious Thumper Offline It only snows seven months of the year here. Posts: 3746 Eastern Michigan Gender:	Re: Fuel flowing out onto the tank from cap Reply #2 - 07/30/09 at 20:11:20 Ah, a good tip there.
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LostArtist Ex Member	Re: Fuel flowing out onto the tank from cap Reply #3 - 07/30/09 at 20:18:38 so, uh, you put a cork in it??
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Tonydtiger1971 Senior Member Offline Yet while we were sinners Christ died for us Posts: 493 Dawsonville, GA Gender:	Re: Fuel flowing out onto the tank from cap Reply #4 - 07/30/09 at 20:22:21 That's one way to do it, I've been looking at seals off of toilets, they look to be about the same size. LOL. Where did you get the cork from?
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LostArtist Ex Member	Re: Fuel flowing out onto the tank from cap Reply #5 - 07/30/09 at 21:23:47 jack daniels
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KenGLong

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2002 Savage

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Albuquerque, NM
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Re: Fuel flowing out onto the tank from cap
Reply #6 - 07/30/09 at 21:28:11

Tonydtiger1971 wrote on 07/30/09 at 20:22:21:

Where did you get the cork from?

I happened to have a package of bulk gasket material that I bought from NAPA a long time ago. It was several sheets of various material in various thicknesses. I still had enough of the cork material left to cut out a donut gasket for the cap. I didn't do a real neat job of cutting it out but it seems to be working fine.

The cap fits a bit tighter now too. I have to press down to get it to click into place.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Fuel flowing out onto the tank from cap Reply #7 - 07/31/09 at 09:14:31 The cap fits a bit tighter now too. I put a thick piece of rubber in mine & had to cut some relief in the lock assy, but yes, I have to push down now to open or close it & I have only seen it dribble a bit once since the mod. Im just not as careful at fillups as I was & have much less problem.
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matt

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Winter Springs, FL
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Re: Fuel flowing out onto the tank from cap
Reply #8 - 07/31/09 at 10:52:32

Now that is a extreamly useful tip! ( perhaps can be added to the tech sections TOC?)

Most everytime i fill up right below the bottom of the filler neck peice and always gushes everywhere!

Not that i dont like the smell of gas, sometimes i miss a little after im whiping up the excess and it leaves marks on the tank :'( .

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jowamf YaBB Newbies Offline love my zuki! :) Posts: 25 New Mexico Gender:	Re: Fuel flowing out onto the tank from cap Reply #9 - 07/31/09 at 14:57:17 I had the same problem once. To the post about getting the air out, that is a good idea. I also would suggest standing the bike upright while filling up. I have been doing this since the leak happened, and have not had that problem again.....just a suggestion.
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Tonydtiger1971 Senior Member Offline Yet while we were sinners Christ died for us Posts: 493 Dawsonville, GA Gender:	Re: Fuel flowing out onto the tank from cap Reply #10 - 07/31/09 at 14:59:26 Got the gasket material, all that had was 1/16th of an inch I may have to double, I need gas so I'm trying with one layer and see what happens.
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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Fuel flowing out onto the tank from cap Reply #11 - 07/31/09 at 15:07:55 I fill mine up on the kick stand I've never had air in the tank of any bike I ever had,Unless it only happens in the hotter climate states.I just go very slow the last 1/2 gallon.Never had a gas cap leak either.
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FreeSpirit Serious Thumper Offline Joy is my Compass ! Posts: 3823 North Georgia Gender:	Re: Fuel flowing out onto the tank from cap Reply #12 - 07/31/09 at 16:47:50 Must be a hot weather thing. I've seen guys "burping" their bikes all my life. Course I've always been in hot climate areas. The gasket tip is a good one! (Hope I can remember that when/if I need it
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serenity3743

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Black Mountain, NC
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Re: Fuel flowing out onto the tank from cap
Reply #13 - 07/31/09 at 17:37:03

I've done the gasket thing too, but sometimes I have noticed that the gas will still seep out through the key hole. My working rules are: don't fill past the bottom of the filler neck with the bike on the sidestand; "burp" the bike before taking off; and don't fill up and then leave the bike in the hot sun. Along with the gasket this seems to work for me.

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2000 LS650P Suzuki windshield, luggage rack, saddle bag racks, k & n air filter, Dyna muffler,2/3 white spacer, do-it-myself seat. Love to ride!

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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Fuel flowing out onto the tank from cap Reply #14 - 07/31/09 at 18:03:25 Thats a new one for me,How do you burp a bike.
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