OEM fuel tank cap gasket replacement options
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  1. #1
    Junior Member dreynolds's Avatar
    Join Date
    Apr 2013
    Clearwater FL
    I am restoring a 1990 TW 200 and need a source for a replacement fuel cap gasket for the OEM tank. Yamaha only sells the fuel cap for around 90 bucks. Ouch! My cap is fine, all I need is the gasket! Alternately, what gas/alcohol resistant material should I use to cut a new gasket? does anyone have the correct dimensions, particularly the thickness? I hesitate to get the thickness off the cracked remains of my gasket. I searched the forums but didn't find a solution. Thanks! UPDATE at lower post. sorry I didn't realize I could edit my prior posts...

  2. #2
    Senior Member Point37's Avatar
    Join Date
    Sep 2011
    Southcoast MAsshole
    someone was making gaskets...not sure they are still around though...


    someone got a gasket from a Kubota to work...


    some have found usable replacement caps as well...


  3. #3
    Junior Member dreynolds's Avatar
    Join Date
    Apr 2013
    Clearwater FL
    Thanks for the advice. I PM'd the member who was helping with gaskets several years ago but haven't heard back. No Kubota dealers near me and they want $18 to ship a $5 gasket. Nuts to that. I like the locking gas cap, so I don't want to replace with a non-locking version.

    Here's a couple of solutions: my local Goodyear rubber store wanted to sell me a piece of 1/8" nitrile 12" x 36" for $18 bucks. great if you want to make a boatload of gaskets. but I just need one! But he convinced me that Nitrile is the way to go. Moving on, I looked on Grainger.com because there is a Grainger store nearly everywhere. so here's the deal get the nitrile Flange Gasket,Full Face,1 1/2 In, 1/8" thick nitrile Item no: 4CYU3. cut it 79mm OD and 59mm ID. (measure your cap in case my 1991 is different than yours! cost $1.41. get two in case you screw the first one up. it will cost less than gas to go back.

    pinned it to a piece of cardboard. I couldn't find my gasket cutter, so I used a compass to draw the two circles and a scissors to cut it out. instant no more gas sloshing out! a dab of silicone grease and back on the road! hope this helps someone the way these forums have helped me!

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  5. #4
    Senior Member Omega Man's Avatar
    Join Date
    Jan 2012
    "It's more fun going fast on a slow bike than going slow on a fast bike" UK

    1994 TW200, 2009 F800GS loaded,

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