so its a 03-04 636, o-town dent... it seems to leak after every thing ive tried... still the stock gas cap... ive tried making a rubber gasket to go behind the stock one (to push harder down before when it latches) still would leak...

then i tried putting jb weld on the tank and grease all around the cap (so it doesnt stick to the seal) and shut it to try and seal up where it leaks... it would work for about 7 circles then start leaking again and the jb weld would be dry


i dk if i should try a vortex, but heard they leak too

any help would be great

 

sell your bike n get a honda you sure theres not a crack sumwhere????

 

i got a vortex and it leaked uncontrollably, i did everything i could think of to get it to stop and it wouldnt
i ended up with a new tank and stock gas cap and it leaked just a little bit after i dented it. i put a longer screw with a wider flat washer in the top bolt of the cap, tightened it so it would push the middle part down and it only barely leaks when i fill my tank all the way up.
you should try it, here's pics hopefully you can tell what i am talking about

 

so then you tighten the screw once you fill up on gas?

 

been through my mind... but im in love with my 36 too much

yea no cracks looked for those first

 

try putting brake fluid on the gasket it will make it swell. worked on my f4i...

 

my vortex does not leak at all. but the stock one did not either

 

EXACTLY
i dont know about your cap but just about every gas cap i have seen on a 636 it sticks up past the base, having that washer there will push the cap flush with the base when you tighten the screw. thus sealing it better. worked great for me

 

and yes.....i have to have a phillips head handy every time i fill up on gas, but its worth not getting gas ***

 

Hmm interesting

Gas *** sucks I have had a bunch of 636 tanks leak. I am gonna try the screw method. Can't you just grind those washers so you can open the cap without carrying a phillips. Or is it the cap won't open unless the screw is loose?

 

The washer is actually what is applying pressure to the cap. It is compressing the springs and forcing a tighter seal with the tank.


Kinda fugly, but functional.

 

here it is pretty much the same dent as yours *****

 

great idea I almost did the same thing, you are very close to the fix but not quite.
I had the super leaker cap on my f4i after denting my tank and saw the front lip sticking up and was going to go with your idea, but I was thinking "WHY IS IT LIPPED UP IN THE FRONT??"

ANSWER; it's because when we smash in the tanks the rear mounting locations distort and GET LOWER than they are supposed to be in relation to the actual top of the hole causing the cap to sit all crooked when it's latched cause the back is actually too low.

SOLUTION just slip a washer UNDER each REAR mount hole under the cap and then tighten as usual and there should be no more gas ***.

NOTE might take some trial and error with washer thickness and numbers. I used 1 lock washer on the back of both bolts for mine.

 

my stock cap stuck up higher than yours and still did not leak

have you tried a vortex it might fix it

i need to bondo and paint mine it looks like poop

 

i think im going to try the washer idea and darrick's idea and if those dont work ill be getting a vortex.. hoping to get it squared away before the indy ride... this **** pours gas to my passenger seat

 

My stock cap sticks up higher than those pics and it doesnt leak. Did you cut down the splash guard inside the tank?

 

if so just get one off this guy. token did and it is the same as vortex just cheaper. my vortex cap went on jasons no problem.

save some $$$

http://cgi.ebay.com/ebaymotors/Kawas...mZ260283847385

 

yep cut it out if you look at the pic of mine looking from the back of the bike at the tank... it looks like when i dented it the right side is down more.. so im thinking the washer idea might work

 

haha i was just looking at those... good call

 

thats probably it. mine is not cut out it just takes a 1/2 hour to get gas but at least i do not have gas *** :YEAH