Having got the bodywork for the NS back on Friday, I spent most of yesterday swapping bits form my spare bike onto the 500 if they looked slightly better than what was on. I then put the newly painted bodywork on the bike and unscrewed the tank cap off the crappy tank and screwed it onto the 'new' tank, after carefully cutting the masking tape off the hole. 2 miles down the road, on a test/shakedown ride, I filled up with fuel. And the first time I braked at anything over about 10% afterwards a load of fuel gushed from the filler cap (yes, it was closed...). On closer inspection the filler opening looked a little bit bent (but only a little bit) so I packed it out with chemical metal to fill in the tiny (approx 2mm deep x 5mm wide) dent and hoped that'd do the trick. Before setting off today, I just held the front brake and rocked the bike heavily back and forth and the fucker still leaks.... So it wasn't the filler hole itself. Any ideas what may be the cause of the leak? The cap never leaked on the tank it came off so the rubber is fine. How far back should I trim/scrape the new paint around the filler cap (I can go back quite a way from the actual hole due to the dustbin sized cap, but I'd rather not scrape new paint off if I don't need to...)? Should I just buy a 1-2mm piece of petrol resistant rubber and cut a piece that fits round the filler hole to create a better seal? Where would I buy such rubber cheaply? Any useful help/comments gratefully received. Dave
