I"m using the original bolts that held the savage petcock on.  the washers were just thin metal, no rubber inserts? don't know about special washers? really don't recall them at all. nothing in the parts can either???

don't know how to verify if it's tank seam is leaking.  

the gas is behind the raptor not in front at the lever.

But it sounds like I got a washer problem??? Never saw any rubber insert washers.?  whatever, the stupids again.

where can I get them... Auto parts store, ask for what??

thanks.

http://www.partzilla.com/parts/search/Suzuki/Motorcycle/1996/LS650P/FUEL+thin...

Alt: http://www.partzilla.com/parts/search/Suzuki/Motorcycle/1996/LS650P/parts.html

# 4 in the picture.


EDIT: Link not gong to the "Fuel C0ck" section for some reason.  Click that then look at #4.

one of the forbidden words alternate added- V1

Hey Wakosama, sorry to hear you are still having issues with the bike. I went for a little ride on Saturday and Sunday in the car I saw a guy on a bike that looked like a Savage and thought maybe it was you.

Get that sucker working and let's go for a ride. If I can help with anything just let me know.

Good day,

Used the new OEM washers and smears of Permatex gas resistant sealant.  Still no leaks, no vapors; and it runs.

Thank you for all the help.  We are grateful.

Happy Easter

When you removed the original petcock...likely the paint chipped off and now the bottom of the tank is uneven, and the O-ring can't get seated.  Not sure what sealing you used - but it sounds like it worked up until the fuel softened it up.

Somehow you need to get the bottom of the tank smooth where the petcock O-ring seals.

So I dried off the petcock and waited.  it stayed dry.  

BUT... it feels like the gas comes from farther under the tank, leaks down behind the petcock,  then down to the lower left corner of the tank underneath where I find the wet gas... 20 min after wiping, wet gas underneath [petcock still dry].  wow...

so you actually did help me fix/replace the really broken petcock... and it still works.  And it's something else.

any other notorious leaks under the tank?  LOL right?  thanks

Dang, sounds like a pain.  These really are reliable little bikes.  You just need to get this one sorted out.
Has the bike ever been down or sustained any impact to the tank?

At this point, it may be better to take the tank off, fill it with a little gas and visually inspect for the leak.  With the Raptor, you don't have to drain the tank to remove it.  Just turn the petc0ck off, disconnect the fuel line, unscrew the speedometer cable (careful not to lose the o-ring on there!), begin to remove the tank and reach under to disconnect the electricals.  Be sure you have a place ready to set the tank down already; folded up towel or such.  All this after removing the seat, of course.

Put some gas in there and visually inspect for the leak.  If it's a seam, it may be easier (and certainly quicker) to pick up a used one rather than get your repaired and repainted.

My gas cap will leak if I get too enthusiastic and fill up into the neck.  It won't leak until I tip the bike upright off the side stand.  That's when I get irritated and look for the paper towels.  I've gotten in the habit of pressing down on the cap while standing the bike up but it doesn't always help.  I do this far too often.

I don't know how much disposable income you have but there are like 2 people selling tanks in the marketplace might be easier to just grab a new tank if you can strike a good deal.