Bike smelling of petrol - petrol cap gasket

If you're getting strong whiffs of fuel while riding, it may well be your petrol cap rubber gasket.
Mine when inspected had cracked and hardened. I looked online to find Suzuki DO NOT sell the gasket by itself, instead they expect you to fork out for an entirely new petrol cap.

So instead I took the old gasket off, just two screws then you can pull it off, and measure it.

The stock one is a 36mm ID, 62mm OD. Closest I could find is this:

https://www.ebay.co.uk/itm/3MM-THICK-VITON-A-FKM-HIGH-TEMP-RUBBER-WASHER-SEALS-DIESEL-PETROL-OIL-RESISTANT/372632387997?ssPageName=STRK%3AMEBIDX%3AIT&var=641648590394&_trksid=p2057872.m2749.l2649

Which is the same ID but slightly larger OD. I put it on as it was without cutting it to size and there you go. It sits on the tank noticeable more 'cushiony' now for lack of a better word, and after several long rides I can confirm it is sealing properly with no issues at all. Here is a photo after a long ride and removing the cap:




As you can see the fuel is not escaping the cap and no more fuel smells! Hope this helps as it took a while to find a premade gasket, you could of course just buy a sheet of fuel resistant rubber and carve one out yourself also.

Nice fix.   Naughty of Suzuki that.  I'd say that is a perishable item, that should be in stock.

Good fix, Suzuki taking advantage of us nice bikers 

We ain't that nice.    You meet the nicest people on a Honda. 

In fairness when I was researching the problem, Suzuki aren't alone. Most manufacturers just dont sell the fuel cap gasket as a stand alone part, hence the huge amount of aftermarket gaskets sold on Ebay, none of which are 'OEM' official. Just glad its fixed, i like the smell of petrol but not all the time.

My 2003 VS800GL developed a rattling gas cap after about 12 years of riding.  I replaced it with a new one for $60, but eventually the new cap began to rattle also.  A close exam of the cap showed the sharp edges of the sheet metal on the tank were cutting into the little tabs that extend to lock the cap down, decreasing the tightness of the cap against the tank and allowing it to rattle.  My fix was to add two or three of my wife's elastic hair bands around the cap edges.

Nice one Arnold, it's ideas like that that save people a lot of grief, makes this site so good.