TOPIC:

Hi,

My petrol cap is leaking through the keyhole slot, I've already placed the seal between the tank and cap, but the diagram doesn't
seem to show a seal thats inside where the cap lock is. Any ideas anyone?
cheers Pete,

Pete:

Have you checked the overflow vent tube? (Internal to the tank) The one that vents overboard near the tool tray. Then there is a rubber hose that extends beyond the frame and exhaust, (muffler cans.)

Take some compressed air with a rubber tipped nozzle from the outside to back flush it.

I don't think the upper portion is accessible from the top inside of the tank.

(This won't cure the vent issue but will assist with fuel going overboard properly, instead of coming out of the top of the tank.


In the early 80's I had the same problem with a 1979 MKII tank. Under hard acceleration and hard braking, fuel would rush out of the cap area and wash-over the hot engine. (Which was exciting) Kawasaki went as far as warranting the tank, but in the end, it ended up being the vent system in the cap. The Dealership drilled the two holes on the side of the cap to a larger diameter and that cured the problem.

Have you pulled the cap completely apart? They have a tendency to rust and corrode with all of the condensation in the tank.

When the cap goes back together make sure it goes back together properly. Last year, I installed a seal wrong on my Z1R fuel cap. This caused the tank to not vent (Opposite of your problem but just relaying the School of Hard Knocks.)

I have seen new seals and service parts available via ebay.

Hope this helps.

T.

Todd is 100% on this one ( as most times !)

The cap has a channel inside to a pressure release to the pipe through the inside of the tank & out through the back under the seat.

Either the seal is not working or the pipe/tube is blocked.

Have a look on the parts diagram , its all there.

Pete F
UK

Ok thanks guys,

now that you mention it, I do remember when stripping the tank down to metal in prep for a respray I did have a go at trying to unblock the breather pipe. I used an airline with a rubber pipe, but no good , I think whatever dirt or rust is in there its solid.
I've got an old clutch cable I might be able to attack it with.

cheers Pete.

Pete,
If you CAREFULLY use a small pipe & some turpentine or thinners, you can pour it down the hole to soften what is in there now & see if it exits at the tail pipe at the rear base of the tank.
Obviously watch you paintwork, but this will help loosen things up !

Pete F

Another item that can clog these tanks are the plastic tank liners.

When they get rolled around while they are being coated, that vent tube can become clogged when the chemical dries. Some of that stuff is pretty tough.

T.