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FWIW I discovered that some Honda caps fit the early TW tanks perfectly. This one came from my ATC Big Red, but odds are those from other Honda ATV's and street bikes may fit as well if you're having issues. Some may even fit the later tanks with the small diameter caps:



 

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Tirebiter - Did you have any luck finding a fuel cap gasket? Mine doesn't sound quiet as bad as yours but has seen better days on my '95. I was surprised that this isn't available as a separate part. The Honda ATC gaskets are available but wanted to confirm they work before buying one.
 

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Tirebiter - Did you have any luck finding a fuel cap gasket? Mine doesn't sound quiet as bad as yours but has seen better days on my '95. I was surprised that this isn't available as a separate part. The Honda ATC gaskets are available but wanted to confirm they work before buying one.
No I'm sorry to say that bike project lost it's priority to a couple more important ones. I did see where a Kubota generator cap gasket (#12521-41340) is supposed to fit too but there isn't a Kubota dealer near me and the shipping cost is kind of high online. I do need to deal with that soon tho. When I do I'll post back here.
 

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Personally I think it's kind of ridiculous the price they charge for these OEM caps.



The Yamaha part, 48Y-24602-00-00 costs 115 bucks at the dealer or about 80 bucks online from your parts guy de jour. Meanwhile people are selling them on ebay for 105 dollars (and people are buying them.)



I don't get why commonly replaced parts cost so much and yet other parts for the TW are reasonable. A cross reference list with part numbers so we can find them later would be great! The 'gas hole' is huge compared to any of my other street bikes, so I'm no good here in terms of telling you what fits.
 

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I didn't like the look of the stock cap and didn't want it locking so I looked around and found the gas cap off a Yamaha FS1 fits perfectly. I bought a reproduction one off eBay for like $27. It's chrome with the Yamaha fork logo on top. Works great!
 

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They exist, but I don't have any more. But FYI here are the two sizes for older and newer tanks.



They are vintage; I doubt they are being reproduced, but they may have been used over a far greater span of years than any of us realize. My shop guys salvaged a bunch from a throw away bin behind a Yamaha dealership a couple of decades ago.

Proudly display the tuning forks if you can get them. Tom
 

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Same type of cap I bought that was reproduced. Got it from this guy on eBay: http://bit.ly/109Occ9 link probably won't work since I'm posting from my phone but look up 'Yamaha fs1 fuel cap' it comes up with ones with the forks and ones without. Seller is 'yambits' comes from over seas. They sell reproduction parts. I think they're also where I got my fs1 round headlight from for my bike.
 

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Tirebiter - Did you have any luck finding a fuel cap gasket? Mine doesn't sound quiet as bad as yours but has seen better days on my '95. I was surprised that this isn't available as a separate part. The Honda ATC gaskets are available but wanted to confirm they work before buying one.
Finally, I can follow up. I've been at the cabin without internet and other luxuries of life on the grid....but there is a Kubota dealer nearby and I finally got the gasket that was reputed to fit early gas caps. It wasn't in stock but they ordered it and it cost $8. The I.D. is so close to identical to the Yamaha gasket that I can't tell the difference. The O.D. is slightly larger but when I put it on the cap it fits just fine. The thickness is real close but the Kubota part has some ribs molded in. I think that is actually better than just a flat gasket. The lock has been disabled on my cap and it tightens perfectly and doesn't leak when I slosh gas around in the tank. I'll give it a 10.




Pics:



 

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Awesome news, thanks for posting this. Nice shot of the part number, very helpful.
 

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Very nice of you to get this info, as you know, others have addressed this problem before with the gasket and either you make your own or buy a new cap. Thanks Tirebiter, this is greatly appreciated. I will be ordering one for my 87.



+1 for ya!
 

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Ok so since it's not just me having this issue I have a question. Sometime in the next week or so I plan on stopping by my neighbor's shop where they make commercial gaskets so I can make a new gasket for my cap. (His shop has the tools and materials, I have the know how thanks to Uncle Sam.) So should I go ahead and make a couple extras for everyone else? I have an '05 so unless someone can spec out an earlier cap I can't make that one. I'd put them up for just parts and shipping. If anyone is interested let me know. It is an easy gasket to make, I just haven't yet looked into what it will cost.
 

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Here's my information for the gas cap which I presume is wider than the newer ones??



Measurements of the inner and outer parts of the fuel cap:



59.33mm and 81.43mm



Measurements of the gasket I pulled off of it inner and outer:



56.07mm and 79.75mm



The gasket has the three raised rings on it on the under side (rather than exposed.) Someone may have bought the Kubota one for my bike, I'm not sure.



I just wanted to supply the measurements for anyone that's curious or wanting to knock out a bunch of copies.



























 

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I am sure that all that you make will be spoken for in no time. Please make all that you can. I am using an older XT 350 tank with one of the larger caps and could you a new gasket. Please put me on your list. Thanks



Joemama
 

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There's definitely no reason to ever buy a new gas cap for a gasket. They're way overpriced. You can buy sheets of rubber at Home Depot in the plumbing section that'd work until you get something proper. Just use a compass to draw two circles and cut it out with scissors. The gasket doesn't attach in any special way to the cap other than being slightly smaller than the center, so it has to stretch around it.
 

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Thanks Silverhead, I haven't mic'ed mine yet but will when I'm at the shop tomorrow. Talked to my neighbor a couple minutes ago, I'll be heading up to his shop sometime next week. Going to see what I run of gaskets will cost for us. This is where he works http://www.actionbolt.com/ and these guys know what they are doing and are good people. Depending on cost I may have them do it so anyone else who wants one gets a gasket made by a company, not just me. One way or another I will get something worked out for us.
 

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Ok, first prototype is on and started testing it. This will be what I'm running and some will be available, but not many. This stuff is pretty expensive but will last long enough for my unborn kids' kids to be using the same gasket. When scrap pieces large enough become available I'll cut some to size for whoever wants them.



I'm still working on finding the best all around material for these. Since many of the gaskets they cut are large enough that the left over piece is big enough for the tank gasket if I find the right material that they use enough of it will just take a minute for the water jet to do it's thing and we should have some nice inexpensive gaskets. If I can find the perfect combo then the cost with shipping will be very minimal.
 

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MadDawg and others who have contributed to this thread. Good job on jumping in with offers, info, and advice for use of others. Its the community spirit that can make or break this forum and similar venues of interchange. Thumbs up to all. Tom
 

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The gasket has the three raised rings on it on the under side (rather than exposed.) Someone may have bought the Kubota one for my bike, I'm not sure.
After looking at the way the gasket contacts the tank I think I installed my gasket upside down. The flat surface should probably seal against the tank....ribs not exposed.
 
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