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Old 09-05-2017, 10:43 AM   #1
plierouge
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Default KLR250 1988 fuel cap gasket?

Hello!

I have an old 1988 KLR250 in relatively good shape. Obviously, I changed most rubber seals, except with the gas cap gasket, which I cannot find anywhere on the web. Even the gas cap seams to be discontinued.

Anyone can recommend an aftermarket/used gasket I could buy?

Thanks!
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Old 09-08-2017, 10:53 AM   #2
Knobs-on-Asphalt
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Default Re: KLR250 1988 fuel cap gasket?

The gas cap for your bike seems to have been sold as an assembly (part # 51048-1063), without a separate seal. The KLR-600 also used this cap. I'd imagine your best bet is to find a used one with good rubber, or perhaps remove the old rubber and add some new stuff yourself.

Good luck to you!
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Old 09-19-2017, 01:34 AM   #3
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Default Re: KLR250 1988 fuel cap gasket?

You might be able to repurpose the perimeter seal from another car filler cap. They can usually be persuaded out with a small flathead screwdriver, pen, whatever won't gouge the material. I've got the old filler cap in the trunk of the S2000, I might give the gasket from that a try along with the rest of the extended family fleet I'll report back any positive results, the lack of a replacement for that gasket is something I too find irksome, as I've replaced or eliminated the other rubber components of the fuel system.
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Old 10-07-2017, 07:49 PM   #4
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Default Re: KLR250 1988 fuel cap gasket?

2005-2009 prius fuel cap gasket is too large diameter. 2000-2003 Honda S2000 fuel cap gasket is a good diameter for the sealing surface but has a cross section like "C" has no way of being secured between the lock cylinder assembly and frame of the fuel lid. I suppose it could be mocked up and adhered in place with RTV silicone but it would not be an elegant solution.

The original gasket is a flattish piece of material secured by the lock cylinder assembly. Maybe a good gasket could be traced out and replicated with a suitable material.

plierouge, you might be able to get one or a batch of the gaskets made if you have a plastics company that deals in retail amounts of material or does small jobs. TAP Plastics and Redwood Plastics might be options here on the central California coast. McMaster-Carr might also be an option to order a sheet of material to cut your own gasket.
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