Gas cap leak

[herbie]

First fill up on my new Brozz resulted in a wet tank from the gas cap leaking, next fill up I didn't put as much in and it was better. But I like to take long rides sometimes and I like plenty of gas so thought I would try something to see if it would help. I took an O ring out from my trusty ole harbor freight kit and found one that would fit over the locking mechanism and under the rubber seal like in the picture. I only filled it up once so far but it didn't leak at all, I don't know the long term effect of the O ring but I will see how long it lasts.

[NzBrakelathes]

As long as the cap can vent so it doesn’t create a vacuum and stop fuel flow

[goat67]

Originally Posted by herbie

First fill up on my new Brozz resulted in a wet tank from the gas cap leaking, next fill up I didn't put as much in and it was better. But I like to take long rides sometimes and I like plenty of gas so thought I would try something to see if it would help. I took an O ring out from my trusty ole harbor freight kit and found one that would fit over the locking mechanism and under the rubber seal like in the picture. I only filled it up once so far but it didn't leak at all, I don't know the long term effect of the O ring but I will see how long it lasts.

Take a dremel with a cut off wheel to that cap.
In you picture the part that extends down can be cut off to just below the lock tabs.
I had the same problem until I did this.

[ChipToothy]

Originally Posted by goat67

Take a dremel with a cut off wheel to that cap.
In you picture the part that extends down can be cut off to just below the lock tabs.
I had the same problem until I did this.

Can you share a photo of yours modded?

[miraclepieco]

Originally Posted by ChipToothy

Can you share a photo of yours modded?

After:

[chazglenn3]

Same issue with the Brozz I bought. I'll take my Dremel to it eventually.

[PeaceSportsAtlanta]

Originally Posted by herbie

First fill up on my new Brozz resulted in a wet tank from the gas cap leaking, next fill up I didn't put as much in and it was better. But I like to take long rides sometimes and I like plenty of gas so thought I would try something to see if it would help. I took an O ring out from my trusty ole harbor freight kit and found one that would fit over the locking mechanism and under the rubber seal like in the picture. I only filled it up once so far but it didn't leak at all, I don't know the long term effect of the O ring but I will see how long it lasts.

From Bashan
"We designed a vent hole on the fuel tank cap. The fuel can not flow to the engine smoothly if we block this hole. The gas can not flow out if the fuel tank is Vacuum. It is not a problem, most chinese bikes are the same design."


Basically if fuel level is over the bottom of the cap, the vacuum can build up. I need to try @goat76's repair. In theory, I see no reason why it would not work as its just raising the vent hole higher in the tank.

[herbie]

I just wanted to update this just in case someone else has this trouble. The O ring absolutely did not fix the leaking cap, as you guys who have dealt with this probably already knew.
I took a long ride yesterday and filled it up a little more than I have been and it leaked out for a bit. Nothing worse than just starting a long ride smelling like gas, but the wind took the smell away in short order. Anyway today I decided to take the cap apart to more than anything see how the vent works. When I popped the end cap off I found a problem right away, I'll see if this cures it if not I will drill a small drain hole in the side to allow fuel to drain back to the tank like Jerryhawk suggested in another thread. If that doesn't work I'll try goat67 trick and cut the end off and if that doesn't work I am going shopping for a Japanese cap to replace it.

[herbie]

The check ball is out of the tube that blocks flow.

[herbie]

I believe this is the correct place for the check ball.

[ChipToothy]

Nice solution buying a new cap. Wonder why the rest of us haven’t thought of that? I’ve had a few rounds of soaking gas out of the tank with the gas station paper towels ha! I want a whole different tank though.

[herbie]

Originally Posted by ChipToothy

Nice solution buying a new cap. Wonder why the rest of us haven’t thought of that? I’ve had a few rounds of soaking gas out of the tank with the gas station paper towels ha! I want a whole different tank though.

Thanks, Yeah I understand the whole new tank thing I was considering making a flat ring and epoxying it to the fill neck to give it a flatter surface for the cap to seal against.

[herbie]

I just wanted to report back about the Honda cap. After about 10 fill ups I have not had any leaks. I fill my tank as full as any motorcycle tank I've had previous and it works perfectly with no leaks, I am calling it a fix!

[Thebrozzanator]

Could you post a link for the gas cap?

[herbie]

Originally Posted by Thebrozzanator

Could you post a link for the gas cap?

This is where I bought mine, but he only has 2 left.

https://www.ebay.com/itm/Honda-New-F...72.m2749.l2649