Filler cap leaking

Hi all

I mentioned this in my valve clearence check but I think it got a bit lost in there, thought a new thread is more appropriate.

A while ago I mentioned how I could smell fuel after taking the cover off in the morning.

And yesterday I discovered fuel will leak quite badly if I lift the tank for more than 3 mins or so. Definately coming from the filler cap.

Its fine otherwise (when its down) so I'm thinking some seal/gasket has gone.

Haynes doesnt seem to go into enough detail - just the removing/installing of the tank in general. Robinsons list the whole cap as a set.

So is this even repairable without getting a whole new cap set? What then of the key?

Thanks

[flymo]

Originally Posted by hongman

Hi all

I mentioned this in my valve clearence check but I think it got a bit lost in there, thought a new thread is more appropriate.

A while ago I mentioned how I could smell fuel after taking the cover off in the morning.

And yesterday I discovered fuel will leak quite badly if I lift the tank for more than 3 mins or so. Definately coming from the filler cap.

Its fine otherwise (when its down) so I'm thinking some seal/gasket has gone.

Haynes doesnt seem to go into enough detail - just the removing/installing of the tank in general. Robinsons list the whole cap as a set.

So is this even repairable without getting a whole new cap set? What then of the key?

Thanks

is there a seal that you can see as you lift it? You may be able to remove it and give it a good clean in hot soapy water. Also, give the locking tabs a spray of lithium grease to make sure they are closing properly.

You should be able to pick up a replacement cap fairly easily.

I'll have a looksy and take a few photos

Could you please show me what I should be looking at? Did an inspection and nothing seems to be obviously foobared.



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How do you fill up....ie, do you rest the nozzle on the side of the filler, or do you keep it from touching the filler...
I used to rest the nozzle when I was filling up and managed to slightly distort the tank filler. ...only reason I found this out was because it let water in too.
Some grease as suggested should help..


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Hmm, I think I do a bit of both. Sometimes I hold it away, when I'm feeling lazy I'll rest it in the neck. I think given the amount of time I've had the bike, the habits of previous owners would have more effect.

Still not sure where I should be greasing...

Whatever is causing the leak is enough to cause a steady stream of fuel to drizzle out when the tank is up...I'm not sure grease alone is going so solve the problem?

[flymo]

ok, so that black rubber ring is the actual seal, it may just have aged and not be sealing or it may be that the latch isnt latching properly. The metal ring section on the tank itself (where the rubber seal sits when closed) doesnt appear damaged from the photo bit take a close look to make sure.

Now, the metal ring part is itself sealed to the tank albeit out of sight, it may be this seal that is leaking. With the filler cap open, very carefully lift the tank so that the fuel is visible, you may see fuel leak from around that metal ring. If its that then its nothing to do with the actuall filler cap. Grease should be applied to the latch itself, thats the pointy springy thing sticking straight up in your photo, spray lithium grease behind it to make sure tha the mechanism operates properly when you close the filler.

Check all the allen bolts that hold the entire assembly together for tightness. You may need to nip them up a little.

Thanks Flymo!

SHall have a gander in a bit, just need to cab some people around.

I did notice that when the cap is closed, I can press the cap down another 0.5mm-1mm or so...normal? or should it be solid and no further movement possible downwards?

[flymo]

Originally Posted by hongman

Thanks Flymo!

SHall have a gander in a bit, just need to cab some people around.

I did notice that when the cap is closed, I can press the cap down another 0.5mm-1mm or so...normal? or should it be solid and no further movement possible downwards?

it should be firm, the seal should seat itself a few millimeters before the latch engages.

Sounds to me like the seal is knackered assuming everything is tightened up as it should be. The latch should engage against the front underside of the tank nozzle, check it with your finger but be careful as it may be sharp. Check its not distorted or worn.

Well I had a good ol' gander and I cant see any obvious distortion, or wear or damage.

I dont have enough fuel now to see if it leaks when propped up

The only thing as I mention is that seal doesnt seem to seat fully, as I can still push it down further by hand.

How do I replace that seal? RF only seems to do the whole cap set...can I retain my key or does the whole cap come as one unit?

Least its still very rideable, for now I just have to make sure I drain the tank or hanve it half empty before lifting it.