Return to the leaking gas cap

[bobhamlin]

About a month ago, I wrote of a problem with a leaking gas cap. When I filled it to the bottom of the splash guard, I had a leak for about 10-15 miles-- gas would seep from the cap. Per some suggestions, the problem seemed to be a missing O-ring ("Oil seal," according to Kaw microfiche). I ordered one, installed it and, because I kept filling the tank in the dark and riding, I couldn't verify that the problem was solved--even though I thought I smelled gas.

Today, I filled it in daylight and the leak is still there. The seal didn't solve the problem. The O-rings for the cap hinge are in place. Several others here said they had no O-ring from the factory, several just never fill the tank to the splash guard.

I think I should be able to fill the tank, but what's the problem? BlownDodge solved it by removing a plastic diaphragm. Garry responded that the diaphragm prevented gas from spilling if the bike tipped.

My tendency now is toward BD's solution. However, I don't understand what is actually happening. We have drain and breather tubes (could something be clogged, or pinched?), one of which is supposed to get rid of gas safely beneath the bike.

To me, this is a serious design flaw. Kaw has to know about it. And once they know, they should be taking some type of action-- or the first time some of the gas ignites, it could be a gruesome court case.