SuzukiSavage.com - Fuel Cap Upgrade

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Fuel Cap Upgrade (Read 39 times)

digitaltrucker

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Fuel Cap Upgrade
07/02/25 at 04:58:33

Here's my solution to the eternal problem of the lousy fuel caps on these things. I got one of these first.

https://www.amazon.com/dp/B01N5FSDDA?ref=ppx_yo2ov_dt_b_fed_asin_title

The spud reasonably fits the hole in the tank. I secured it with JB WaterWeld putty, supposed to be gas resistant and suitable for tank repairs. It's the white stuff.

It cures quick and after it set overnight I painted a layer of regular JB Weld over the top. First trial it seems to do the trick, I guess I'll find out how well it holds up. So far no leaks and no seepage. I'll worry about making it pretty once I'm sure it will work. A dab of filler and a shot of paint should do the trick nicely.

FuelCapUpgrade.jpg

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2652 Amongst the Twisty Roads	Re: Fuel Cap Upgrade Reply #1 - 07/02/25 at 13:05:25 The perfect solution for a problem that doesn't exist.
Back to top	A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged

digitaltrucker

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Re: Fuel Cap Upgrade
Reply #2 - 07/02/25 at 15:43:29

You mean the problem of fuel constantly seeping out around the stock fuel cap, even on a brand new machine? The problem of trying to shim up the gasket to help keep it sealed? The problem that replacement OEM gaskets aren't available, requiring one to either roll their own or try to track down a similar Honda part that might or might not be available?

To which of those "problems that don't exist" are you referring?

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digitaltrucker

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Re: Fuel Cap Upgrade
Reply #3 - 07/02/25 at 15:53:25

On a side note, I tested it out pretty thoroughly today. I did get a tiny bit of vent seepage when I deliberately fueled it more than normal (on the kickstand, filled to the bottom of the inner neck). Even so, it only seeped once right after fueling and getting the bike upright and was far less than I've ever seen before.

Bottom line; assuming I fill the tank like I normally do and the JB Weld claims that it's gas resistant aren't terribly inflated it's a success. One nice thing is that the gray JB Weld smoothed out somewhat as it cured which will make it easier to prettify it.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18391 Camp Springs, Kentucky Gender:	Re: Fuel Cap Upgrade Reply #4 - Yesterday at 09:14:54 Where is the vent? Can water get in the vent while washing or in the rain?
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Gary_in_NJ

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Re: Fuel Cap Upgrade
Reply #5 - Yesterday at 12:48:22

digitaltrucker wrote on 07/02/25 at 15:43:29:
To which of those "problems that don't exist" are you referring?

I don't have any of these issues on my 1997 machine...nor do I remember reading on these forums that this is a wide-spread problem. How about just a replacement OEM cap? And if you've tried different OEM caps...then the problem is the fuel filler neck...not the cap.

A life-time student of motorcycling.
LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS
My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 29013 L.A. California Gender:	Re: Fuel Cap Upgrade Reply #6 - Yesterday at 14:55:40 Dave wrote on Yesterday at 09:14:54: Where is the vent? Can water get in the vent while washing or in the rain? looks like it's in the oring Quote: 1/8" Buna-N O-Rings - ONE VENTED and ONE NON-VENTED INCLUDED
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18391 Camp Springs, Kentucky Gender:	Re: Fuel Cap Upgrade Reply #7 - Today at 03:24:05 verslagen1 wrote on Yesterday at 14:55:40: Quote: 1/8" Buna-N O-Rings - ONE VENTED and ONE NON-VENTED INCLUDED That is unique......I never heard of that technology before.
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