SuzukiSavage.com - Leaking filler cap

marekbuk Full Member Offline SuzukiSavage.com Rocks! Posts: 158 West Yorkshire, UK Gender:	Leaking filler cap 05/16/17 at 01:58:26 Guys I'm sure I've seen a link to fixing a petrol cap leak somewhere but can't find it. Has anyone made their own washer to fix a filler cap leak or know of one that fits - I did buy a washer for a Honda cap a year or 2 ago after seeing a link on this forum but it was far to small. Mark
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Leaking filler cap Reply #1 - 05/16/17 at 07:15:28 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1262920654
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marekbuk Full Member Offline SuzukiSavage.com Rocks! Posts: 158 West Yorkshire, UK Gender:	Re: Leaking filler cap Reply #2 - 05/16/17 at 07:22:47 Many thanks Verslagen - thats the link I looked at 2 years ago
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Leaking filler cap Reply #3 - 05/16/17 at 07:43:06 I was looking at this post as well as the previous referenced, but I don't see the part number for the factory gasket and can't seem to find it on diagrams (it is the whole cap kit). I want to just replace my 9 year old gasket with a new stock one. Anyone know the stock gasket part # ?. The Suzuki one, NOT the Honda one. Thanks
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marekbuk Full Member Offline SuzukiSavage.com Rocks! Posts: 158 West Yorkshire, UK Gender:	Re: Leaking filler cap Reply #4 - 05/16/17 at 08:19:16 This morning I looked at the parts list on a Suzuki Dealer site and the schematic only showed a complete cap - ie. no separate washer
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Leaking filler cap Reply #5 - 05/16/17 at 13:47:19 You might try my cheap trick, cut a washer out of gallon milk bottle plastic place it behind the stock gasket (turn the stocker over,make the out side of the new washer slightly smaller OD than the rubber gasket).
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Leaking filler cap Reply #6 - 05/16/17 at 14:19:02 batman wrote on 05/16/17 at 13:47:19: ...make the out side of the new washer slightly smaller OD than the rubber gasket batman, what is the objective in the "milk carton" washer OD slightly smaller than that of the stock? Is it to keep it from getting hung up on the filler cap tabs so it'll slide on easier?
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Eegore Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 8326	Re: Leaking filler cap Reply #7 - 05/16/17 at 14:29:21 Is it a huge issue if there's no gasket at all?
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Leaking filler cap Reply #8 - 05/16/17 at 14:37:02 Eegore wrote on 05/16/17 at 14:29:21: Is it a huge issue if there's no gasket at all? YES. There is nothing to stop fuel sloshing out of the filler hole if fuel sloshes up that high.
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Eegore

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Re: Leaking filler cap
Reply #9 - 05/16/17 at 14:39:45

stewmills wrote on 05/16/17 at 14:37:02:

Eegore wrote on 05/16/17 at 14:29:21:

Is it a huge issue if there's no gasket at all?

YES. There is nothing to stop fuel sloshing out of the filler hole if fuel sloshes up that high.

Right, I wrecked a few times and gas runs out. Guess I need to find a replacement.

Is it easy to get a new cap re-keyed?

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SALB Serious Thumper Offline FSO Posts: 668 Whittier, AK Gender:	Re: Leaking filler cap Reply #10 - 05/16/17 at 14:53:01 marekbuk wrote on 05/16/17 at 08:19:16: This morning I looked at the parts list on a Suzuki Dealer site and the schematic only showed a complete cap - ie. no separate washer Check your local auto parts store, it may be a common size. You could also cut one out of a piece of rubber, if you can find some the same thickness.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Leaking filler cap Reply #11 - 05/16/17 at 14:57:36 https://www.mcmaster.com/#standard-rubber-sheets/=17nmb8k
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Leaking filler cap Reply #12 - 05/16/17 at 14:59:39 My only worry with "making" one like described in the tech discussion is the fact that rubber not made for gas tanks/fuel will not be fuel resistant and degrade when exposed to fuel. Might be good at first, but after a little exposure it may get soft and goopy and/or start coming apart.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Leaking filler cap Reply #13 - 05/16/17 at 16:46:47 Buna N was a common butterfly valve seal. That's some rugged stuff.
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batman

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Re: Leaking filler cap
Reply #14 - 05/16/17 at 17:05:30

First off the fuel cap pic above looks as though some one turned the seal over without removing the two screw to tuck it under the plastic cap that covers the lock pieces. the brown ring shows were the rim of the tank actually seals ,the milk bottle gasket only needs to extend a bit beyond that point ,and if the rubber gasket was laying flat it would extend nearly to the outside of the cap.If you feel a slight resistance (you have to push down on the cap to lock it ) you have shimmed it thick enough to make it seal .

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