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Posted by greenbarn
- July 11, 2016, 21:16:15 PMSo that explains the "CA" on the drawing..... Here I thought maybe it was for CAnada... 
But seriously, even so, I've thought more about this. My screws were not loose - I checked them about a month ago, after I had fuel run down my let twice after filling up. Maybe I was over-filling, but if so I've been over-filling the whole time I've had the bike. I (used to) fill to about half-way up from the "baffle" at the bottom of the fill-neck, to the top of the fill neck - on the side stand, of course, so when you tip it up, the right side gets more full- undoubtedly splashed up against the fill cap. The main cap gasket appears to be fine, so I thought perhaps gas is leaking through the innards of the cap, and out through that hole (which goes to a drain line to the ground). So, maybe if it had a rubber gasket on that nipple, it would drain to the ground, not down the side of the tank.
So I took the cap apart again tonight (I had taken it apart a month ago), and I still do not see anything wrong. Of course, it hasn't leaked since I took it apart last month --but then again, I've been careful to only fill it to the bottom of the fill neck.
SO there must be more than just loose interior cap screws that can cause this problem - and after seeing the innards of this thing again, I can see it's very complex. There are no less than 3 check valves, of sorts, numerous chambers and passages. It seems WAY more complicated than it needs to be - rivaling the complexity of some modern EVAP and other emissions systems on automobiles these days.
So having found nothing to fix on mine, I will install the CA seal, in hopes that perhaps if something inside the lid is not working properly, maybe there's a chance any leaked fuel will still go to the drain. In the mean time, I plan to continue to fill it lower.
Posted by CDNRatMan
- July 11, 2016, 16:56:36 PM 
now I can sleep.......this must be another thing like the labels we get on items from California, it tells you the following
the following items are known in the state of California to cause cancer or to be hazardous to pregnant or and nursing females. That is why I am staying away from California.
Posted by Troll
- July 11, 2016, 15:53:22 PMOk, ok...enough! It's a California only part, meant to seal the fuel system completely to prevent vapor loss. When my cap was leaking, I got one, and put it on. It goes under the cap hinge, inside the ring...but it didn't help a bit. The screws holding the center of the cap to the cover were loose, and the VERY THIN rubber gasket that is supposed to seal the cap was leaking. I took the cap completely apart (not for the faint of heart) and found the REAL problem!
Posted by greenbarn
- July 11, 2016, 15:29:45 PMMoose, eh? Smart A$$.
From what I can tell, it has to go under the gas cap hinge piece, between the tank and the hinge. Otherwise it would fall off when you open the gas cap. A phillips screwdriver is all we'll need to install it.
If we could just get some kind forum member to snap a picture that still has this little gem installed, I guess we'd know for sure. Sounds like a lot of them have disappeared over the years....
Posted by CDNRatMan
- July 11, 2016, 14:58:49 PMHey Moose check out the picture....for me and let me know....
Posted by greenbarn
- July 11, 2016, 11:39:47 AMI just ordered 4 of them from Partzilla. $4 plus shipping -- $5.85 each with the shipping split 4 ways. I need 2, so if anyone needs one, I can either bring it to Wisconsin (assuming I get them in time) or I'll drop in the mail.
Posted by JagLite
- July 10, 2016, 23:14:53 PMHuh? 
Well look at that! 
There is supposed to be a seal there... 
No wonder my tank seeps a tiny bit when the tank is full. 
Thanks for asking, and thanks for the answers! 
Posted by CDNRatMan
- July 10, 2016, 23:02:45 PM now I have to get dressed and go out to the shed at o dark hundred and see if there is anything in mine.....thanks GB......
Posted by greenbarn
- July 10, 2016, 22:09:07 PMI attached a picture of my 1500 fuel cap. See if I have the location correct for what you are referring to. The little "nipple" on the fuel tank cap goes down in this hole. makes sense there would be a seal there.
I've had fuel leak from both my 800 and 1500 -- could never figure out why, now I see I do not have that seal on EITHER bike - no wonder I couldn't see anything wrong because both of them are the same.
Posted by greenbarn
- July 10, 2016, 00:34:02 AMGot a picture of that, or a diagram?
Posted by Gordo
- July 09, 2016, 23:19:19 PMI just went through this with mine. It dribbled out, and I compensated by not filling the tank. I pulled the cap and confirmed all O rings were around top and bottom of the mounting screws. What I noticed was the vent fitting off the tank no longer had the small gasket seal between the tank vent and the mount for the gas cap. Have no idea how or when this went missing, but there was no rubber around the vent. I ordered Kawasaki OEM Part # 92093-1030 online for a couple bucks and solved my problem. Cancelled the order for a new cap.
Good luck
Posted by 49Reo
- June 27, 2016, 21:20:13 PMWhen I got my 1500 the cap leaked when the tank was full. One of the o rings Troll mentioned was missing. New o ring fixed the leak.
Posted by Troll
- June 27, 2016, 14:43:41 PMStart out by making sure that all the screws (including the little, tiny ones), are tight. Check the vent hose to be sure it's not plugged. You will probably need to take it off the tank to get to the little phillips screws, be aware that there are 2 O rings on the large screws, so don't let them fall into the tank
Posted by Old Drifter
- June 27, 2016, 11:28:38 AMYou may also try to cut one from an old rubber tire tube.
Posted by pcarrell
- June 27, 2016, 11:21:26 AMGo to an auto parts store and buy some gasket material and make your own.