Author Topic: HD200 EVO LEAKY GAS CAP?  (Read 230 times)


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« on: January 13, 2020, 05:19:17 PM »
I recently bought a 2014 EVO with barely 300 miles on it. I was going on a very long trip and topped up the gas as much as I could. I locked the gas cap, but after a while, I stopped and smelled gas. Gas had been leaking from the cap. I figured that I overfilled it. Just filled up again but this time made sure to put the pump nozzle all the way in so it wouldn't overfill which worked. But then I stopped and smelled gas and the cap had leaked again (not much but some). Has anyone else experienced this?


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« Reply #1 on: January 14, 2020, 02:09:10 AM »
There have been some cases where the cap wears out the plastic it attaches too and won't seat.
For that hit up alliance and hope they hook ya up.  There are some threads on that. If not it's not a cheap part & it's a pain to get to so replacement's time consuming.

If it's not that then I'd check and make sure that all they vent lines are unkinked.

I'd also immediately check oil and make sure it's not mysteriously overfull and smelling of gas as well as the air filter to make sure it's not full of gas.
08 SYM HD200
07 Suzuki Burgman 650


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« Reply #2 on: May 02, 2020, 03:39:29 PM »
My 2016 HD200, 8K miles, daily rider (most days here in Seattle) and therefore my gas cap gets removed / replaced all the time, and it would be so cool if the tanks were bigger!

Re the leaking gas cap, Tromper is exactly right in that the locking metal ears abrade and wear-down the plastic receiving locking grooves and therefore the cap locking ears are not able to do their job by "grooving" into the plastic adequately, resulting no sealing.  In my case one of the metal ears was missing its mark and not grooving in.  The gas cap was only in at a sort-of angle, not at all sealing correctly.  Gas all over the place upon left turns. 

My fix was the following: 

Remove the cap
Thoroughly clean the top of the filler neck with a clean rag, NOT a paper towel
Apply just a pinch of liquid dry lube to only the plastic grooves, inside and out
Apply a dot of dry lube to the curved (convex) sides of the metal ears
Do not apply any dry lube to the main rubber seal at the cap

Be sure the ears are aligned with the receiving notches
Slowly twist the cap back on
Repeat a few times being sure the ears are in place correctly

This has worked for me so far for the past three months with absolutely no leaks and so I carry a small can of dry lube with me always if the cap does not want to lock and seal correctly in the future.  Also, you will see that your cap will turn and lock much easier too. 

A harder and harder opening and closing of the gas cap indicates the need for the dry lube idea before the cap starts leaking.  Wish I'd known this before. 

Good Luck

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