Gas Caps

[cowboyup3371]

Hey Kparkfan, where did you end up getting your new gas cap?

[kparkfan]

It's hard to believe all the expense and trouble being tossed about to fix this problem. It could be a bad petcock (cracked at a bolt hole), a bad seal in it, usually underneath the lever, or diaphram if it's leaking at the back. It could be a bad O ring or dirty surface if it's leaking where the petcock mates to the tank. It could be a bad gas line connection to the petcock.
But if it's leaking at the bolts, it's more than likely the self sealing Oil Gallery Exhaust washers. Those are special washers that seal the bolts and if they're bad, cracked, or flattened, they could be prone to leak. Try to understand that
these holes the bolts fit through bypass that O ring seal at the tank/petcock surface. To better understand, simply remove a bolt and watch the gas pour out.
If that is where the gas is coming, that's where I'd focus my attention.
Item 4, part number 09168-06023, $1.16 each at Boulevard Suzuki.
http://www.boulevardsuzuki.com/fiche...1982&fveh=2157

I cleaned the surface where the petcock mounts to and replaced the screws washers and oring with new OEM parts. It seems to be leaking from the gasket and down onto the screws. I figure worse case scenario if still leaks with the new petcock I will have a spare sitting around.

[kparkfan]

Hey Kparkfan, where did you end up getting your new gas cap?

I ended up getting it from the U.K. for $32 shipped and got it in less than a week.