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Posted by CDNRatMan
- July 13, 2016, 22:50:12 PM 
remind me never to take that apart.......
Posted by greenbarn
- July 13, 2016, 21:53:51 PMI did not devote the time to studying what possibly could be the reason for all those internal passages. Some of them just appear to go back and forth within the tank for no reason.
Posted by greenbarn
- July 13, 2016, 21:50:54 PMWanna know something weird? The cap on my 1500 is completely different. Similar, but the innards are different. I haven't seen anything so unnecessarily complicated. My 2002 800 ad 2003 1500 appear the same inside. What year is your 1500??
Mine has not leaked from the key hole, but just leaked gas around the fuel cap.
I did notice that (in regards to your plate on backwards) everything I saw would only go together one way - any other way would not fit properly. I wonder what the story is on yours being put together wrong??
Posted by Gordo
- July 13, 2016, 20:32:30 PMWith the plate mounted with the stamped pins down, the plate does not completely seat against the vent tower and key/lock tower. I figured fuel was travelling between the two. In the pic, you can clearly see that the plate is not seated.
The second pic shows proper assembly, with stamped pins up. I put a bit of grease on the top side, and placed it into the housing. The grease held it in place while I assembled it. Screwed everything back together and a test ride confirms no more fuel venting through the key hole of the cap lock.
So I don't know if originally had 2 problems, the vent seal and the plate reversed, or if I reversed the plate when I took it apart several times looking for the original leaking.
I hope I've beat this beast for good!
Posted by Gordo
- July 13, 2016, 20:25:51 PMSo it is finally warm today. I filled the bike up, not stupid overfill, just really filled. As I rode off, fuel bubbled out the key hole when I was stopped in traffic. Obviously a venting issue. Back to the garage, and pulled the cap off, again. What I found was that the plate inside the cap was upside down. Note that the 2 indents, or locator tits are down when I pulled it apart. (Down on the bench, but actually other way up when installed. OK?) Also note that I have already removed a tiny cylinder that rests on the pin of the lock assembly, just above the orange rubber seal. Don't loose that!
On the second photo you can see the 2 locator stamped pins on the plate.
Posted by Pilgrim
- July 13, 2016, 17:56:38 PMthird pic looks like mine...I don't think my bike is a california model.
Posted by Gordo
- July 13, 2016, 17:43:18 PMFirst pic shows no gasket.
Second the gasket over the vent.
Third one shows what it all looks like together.
I've included a bunch of pics from various angles for reference as it seems quite a few have disappeared over the years. This is Canadian bike.
Watch out for all the little "O" rings. I put a towel in the tank to prevent a fishing trip.
Can't seem to get them rotated properly, sorry.
Posted by greenbarn
- July 12, 2016, 10:41:12 AMOh, I saw it all right.... saw it real up close and personal, I did.... 
Posted by CDNRatMan
- July 12, 2016, 10:35:56 AMSorry Big Foot but he is easily distracted, he can not even see a moose on the road.
Posted by greenbarn
- July 12, 2016, 06:30:10 AMQuote from: CDNRatMan on July 11, 2016, 23:26:33 PMHey, you're the one that got us off topic with a geography lesson.Now solve Big Foot's issues.......
I thought we were still working on fuel cap leakage... I don't know if his is the large main cap seal leaking? could be - or could be loose screws inside the assembly, like Trolls. Or evidently there is another mode of interior failure.
Posted by CDNRatMan
- July 11, 2016, 23:26:33 PMNow solve Big Foot's issues.......
Posted by greenbarn
- July 11, 2016, 22:59:08 PMQuote from: CDNRatMan on July 11, 2016, 21:37:07 PM
Ok Moose let me educate you, if "CA" stood for Canada it would have been as CDN but the manual was an American printed book so the "CA" stands for California.
Posted by CDNRatMan
- July 11, 2016, 21:37:07 PM
QuoteOk Moose let me educate you, if "CA" stood for Canada it would have been as CDN but the manual was an American printed book so the "CA" stands for California.So that explains the "CA" on the drawing..... Here I thought maybe it was for CAnada...
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.