Gas Caps: CA vs. The Rest of US (Or "Vented vs. Non-Vented")

1728 Views 4 Replies 2 Participants Last post by larry1096, 10 mo ago

larry1096

Discussion Starter · 10 mo ago

Howdy,

I just swapped tanks (previous one was rusted, then lined over the rust, then peeling....sigh) and found that my '08 650 ABS is actually a California model. This means my gas cap is not vented, and the original tank had a separate hose traveling to a charcoal container for venting the tank.

The replacement tank is NOT a CA model, and doesn't have the fitting for the vent hose. Because my cap is non-venting, this means I need to:
1. Find a replacement cap that will vent (don't really care about key compatibility), maybe an Ebay cheapo?
2. Somehow drill a vent into this cap

Being both chea.....er, frugal and impatient, I'm favoring option #2. Anybody done this, or can offer solid reasons why it won't work/shouldn't do it/"It'll EXPLODE, Larry!!!" kind of stuff?

Thanks,

Larry

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Brockie

· #2 · 10 mo ago

Go back to the supplier of your replacement tank and buy the cap that was on it - and then seal the canister. It is a vacuum system so just seal it unless you believe that a roadworthy annual check might uncover your modification.

Venting your existing cap is difficult as it is a one way system to prevent fuel spill when the bike has a rest.

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larry1096

Discussion Starter · #3 · 10 mo ago

Thanks for the reply. The seller didn't have a matching gas cap, or that would have been a great solution. Suzuki seems to be sold out of OEM units.

I found this thread that implied a non-vented cap could be vented by disassembly and removal of a small plastic part.

If that worked, it would certainly simplify things. Do you see a downside to that mod?

Larry

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