Fuel cap gasket

Sunspark

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Hi, I think I might have a defective (or missing?) gasket. This is something I need to fix the hard way because Suzuki doesn't sell gaskets for the cap they want you to buy the whole assembly for $200. I have read sometimes you can make your own gasket or substitute a Honda gasket of the same size.

I was wondering if anyone else here has had issues with their vented gas cap gasket on a bike from any manufacturer.

The reason I believe there is an issue is because I can smell the gas if I go near the cap despite it having been sitting for months for the winter.

Thanks.
 
I was under the impression that venting usually is supposed to be air entering the tank not exiting. It has been sitting in subzero temperatures since December. I shouldn't still be able to smell gas at the cap or should I?

When I was at the February show the same bike I have but newer didn't have the odour at the cap. Maybe they drained it dry? The odometer did say 91+ KM so it had been driven..

Asked another guy and he said his older bike didn't have it even indoors. Said for me to check under the tank but I think it's the cap first.
 
You'll have to tell us what year/model of Suzuki you are talking about. Yes, older ones vented through the cap, but newer ones do not. So it may be OK as is, maybe not. Does the online parts fiche show a vent hose for your bike?
 
I wouls be looking for a leak rather than the cap. I have worked on really old machines where the gasket was cork and degraded to the point og no return and couldnt smell gas. Likely a line,carbs,petcock leaking. Also if carbed check your oil. Gikes sitting a long time can leak raw fuel into the cyl there it leaks past the rings and fills the crankcase thinning the oil out. The crancase is vented and that could be the cause of the odor.
 
It's the 2012 TU250X (and has EFI). There is no vent hose, it is vented through the cap. The fuel pump is inside the tank itself. So the only thing outside the tank would be the hose (with attendant gaskets I guess) coming out with a pushbutton disconnect fitting at the bottom where it attaches to the engine.

Fuel tank:

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Fuel pump:

Photo%202014-03-11%208%2003%2059.png
 
or fuel pump gasket. Injector rail/manifold just very unusual to have gasket causing a problem especially in something this new.
 
Smelling gas by your cap is normal. I have old tanks with no gas in them and the cap still has a lingering smell of gas (tanks been dry for 2yrs).

How have you come to the conclusion that that your gasket is defective?
 
Smelling gas by your cap is normal. I have old tanks with no gas in them and the cap still has a lingering smell of gas (tanks been dry for 2yrs).

How have you come to the conclusion that that your gasket is defective?

Several things. 1 being the bike at the show had no odour at all. It is possible that it was drained for the show for safety and then washed combined with good hvac. Another being a guy with the same bike said to me that he had his in his house and didn't notice anything by the cap. Another being forum posts talking about how on their bike of different vehicles saying that sometimes the gasket is installed upside down via error especially if the gasket has a rib or rim on one side but not the other and flipping it over helped resolve the issue, etc. The ones talking about the odour also tended to be the ones with visible leaking especially when tank filled high and leaned or bike tipped on side. If fluid can pour, so can air.

2 years? That's surprising to me. Wouldn't it have outgassed dry after that long?

I think at this point I need to look at my cap. I can't even remember now what the underside looks like. Maybe it has nothing at all except those spring loaded metal wedges. I do remember that when I push down on it a bit it springs back up a little. I try to lock it while pushing down on it. I will have to see exactly how it vents. The only hole visible from above is the keyhole that I can remember.

I know it'll never be "perfect" but I do want it to at least be "comparable" to others.

What's interesting also and probably unrelated completely is that when I first got it I noticed that if I turned it off with the kill switch I could smell gas in the garage for much longer. So I got into the habit of turning it off with the key instead mainly because it's what some Harley owners had to do to burn up the rest of the fuel in their system for whatever reason when parking. It did seem to make a bit of difference but I am not sure why between switch and key either.
 
Several things. 1 being the bike at the show had no odour at all. It is possible that it was drained for the show for safety and then washed combined with good hvac. Another being a guy with the same bike said to me that he had his in his house and didn't notice anything by the cap. Another being forum posts talking about how on their bike of different vehicles saying that sometimes the gasket is installed upside down via error especially if the gasket has a rib or rim on one side but not the other and flipping it over helped resolve the issue, etc. The ones talking about the odour also tended to be the ones with visible leaking especially when tank filled high and leaned or bike tipped on side. If fluid can pour, so can air.

2 years? That's surprising to me. Wouldn't it have outgassed dry after that long?

I think at this point I need to look at my cap. I can't even remember now what the underside looks like. Maybe it has nothing at all except those spring loaded metal wedges. I do remember that when I push down on it a bit it springs back up a little. I try to lock it while pushing down on it. I will have to see exactly how it vents. The only hole visible from above is the keyhole that I can remember.

I know it'll never be "perfect" but I do want it to at least be "comparable" to others.

What's interesting also and probably unrelated completely is that when I first got it I noticed that if I turned it off with the kill switch I could smell gas in the garage for much longer. So I got into the habit of turning it off with the key instead mainly because it's what some Harley owners had to do to burn up the rest of the fuel in their system for whatever reason when parking. It did seem to make a bit of difference but I am not sure why between switch and key either.
'

I am really not sure what the problem here is. If you are feeling that the gas cap is not sealing the way it is suppose to (which is unlikely) take it back to the place where you purchased the bike and have them inspect it and record it.

If this was purchased privately, take it to KEN - kneedragger88 from this forum, he runs a shop and have it fixed.

The smell of gas is subjective. Motorcycle show = lots of space, lots of air movement. Your garage , smaller amount of space, less air movement = higher concentration of odour / petrol molecules will be present.


If you are looking for material to seal your cap, you can find gasoline/solvent safe sheet stock at a indudustrial supplier. If you need a O-Ring type of seal, you can find it there as well. Most SS bikes and the newer stuff I see have flat gaskets

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