Motorcycle Repair: Fuel leak from tank cap, kawasaki vulcan 1500, brown streaks

Question
Hi Mark

This may be an easy one for you. I have a 2005 Kawasaki Vulcan 1500 Classic. Its fuel injected but I don't think it is considered an FI. Every time I fill up my gas tank, fuel leaks out of a hole in the the tank next to the gas cap. The hole is right under the right side of the gas cap. It looks like its supposed to be there so I don't think I can just plug it up. I have to shove a napkin in the groove around the cap to keep gas from running down the tank. I tried not putting as much fuel in the tank but it has to be like a 3/4 fill up. I only have 4.2 gallons to begin with, 3/4 of a tank really bites. I already have to repaint the tank because the gas has discolored the paint and I can't get rid of the brown streaks running down the side. I hope you can help me. I want to get the tank painted but there is no reason to until I fix the leak problem.

Thanks in advance and I hope to hear from you soon.

Answer
Hi Gerald,

I suspect the cap's atmospheric vent is leaking. This is the first complaint I've heard of this problem.

Inspect the cap seal and vent for defects and evidence of varnished fuel, etc... Clean or replace the cap accordingly.

Visit "www.vroc.com" and inquire with other Vulcan owners about the problem.

Respectfully,
Mark Shively