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2004 XL-7 Radiator Cap - aftermarket options?
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Author:  murcod [ Mon Mar 09, 2015 10:18 pm ]
Post subject:  2004 XL-7 Radiator Cap - aftermarket options?
I've got a 2004 (updated model) XL-7 and am having problems locating an aftermarket radiator cap. This is the model where the cap is located on the engine - not on the radiator (like I believe the early models are?)

So like this:
Image

not this:
Image

Tridon list CC16110 - but that is too small to fit (I assume it would fit the earlier model XL-7?)

I worked out that a Tridon CB16110 should be correct, but I still had to modify (grind down) the metal tabs on the underside of the cap. They protruded too far and fouled on the aluminium filler neck, making the cap hard to turn (perhaps poor quality control at Tridon?) Apart from that it seems the right fit- holds pressure okay and is the correct pressure rating. On the OEM cap the tabs are concave to clear the filler neck- the Tridon cap just has square edged tabs (and they didn't even appear to be of equal length :roll: )

PS: I've owned the XL-7 for just over 7 years and this is the second time I've replaced an OEM Suzuki cap- due to the top rubber seal cracking. At over $40 a pop I'm not keen on buying OEM again, especially given their life span! :x
Author:  GeckoXL7 [ Tue Mar 10, 2015 1:02 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
I havent had much luck with Tridon caps, i had the original Suzuki one for 205,000 ks before i replaced it (water Pump) put a tridon on last a few months and started leaking, went back to the cap that came with the new radiator.

Try finding a gates 31412 cap Might have to be a rock auto order unless Bursons or Repco may sell them.

Pretty much the cap falls under 16PSI Jap Extra Small.
Author:  murcod [ Tue Mar 10, 2015 1:51 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
You'd have the earlier version with the cap on the radiator? That matches with the Tridon listing of "Japanese Extra Small Bayonet" style - like you mention. Mine appears to be the "Japanese Small Bayonet", which is the next size up. The only issue with the Tridon cap (quality wise, from a visual inspection) is the pressed metal top with the tabs perhaps not being cut correctly to spec. It's been driven a couple of times since and appears to be working fine and holding pressure.

This is the one you'd have CC16110:
Image

and this is the one I've got fitted (with modified tabs) CB16110:
Image

The caps not lasting on mine might be something to do with the cap being fitted onto an alloy filler neck, whereas yours goes onto the plastic radiator filler neck? The top rubber seal (which comes into play when the cooling system siphons back the coolant from the overflow tank) develops cracks from the outside edge. Luckily, I've noticed it before the cracks have opened enough to break the seal between the cap and filler neck. If that seal cracked enough the cooling system would siphon air back into the radiator.
Author:  GeckoXL7 [ Tue Mar 10, 2015 2:03 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
Mine does go on to the raditor but from what i see when doing a search comes up with the same radiator cap part numbers for 02 or 04/06.
It could possibly be a 16Psi Jap small cap.

Ive got a gates cap in the back of the car ill have a look and compare to your pic. But from memory i think it is a small valve like the top pic.
Author:  murcod [ Tue Mar 10, 2015 2:36 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
Yes, that's the problem I've come across - the listing is the same for all year models but that specified cap is too small for my 2004 model.

Some more searching (Rockauto and Amazon) shows a Gates 31366 or Stant 10233 (seem to be the same cap from Rockauto's pics http://www.rockauto.com/catalog/moreinf ... 385&jpid=2 http://www.rockauto.com/catalog/moreinf ... 385&jpid=3 ) should be the correct fit. I found both of them by weeding out the listings that were common for both 2004 and 2002 models.

I can get one delivered from Amazon for US$12 !!! You can't beat Amazon's freight costs.
Author:  GeckoXL7 [ Wed Mar 11, 2015 8:36 am ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
Checked my gates cap, good quality but i see what you mean each side is on a slight slant downwards not straight.

I reacon you prob do have a Jap small instead of extra small.
Author:  murcod [ Wed Mar 11, 2015 4:00 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
Yes, the diffculty with fitting the Tridon CB16110 "Jap small bayonet" just threw some doubt into my head..... I was wondering if it's some bizarre non standard size cap?

At this stage I'll just keep an eye on the coolant level and see how it goes.
Author:  murcod [ Sat Mar 14, 2015 12:13 pm ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
Further info:

Genuine Suzuki Radiator cap for 2004 model (cap on engine) appears to be 17920-65G50

For earlier model (with cap on radiator) it appears to be 17920-75F00
Author:  murcod [ Sat Apr 04, 2015 10:33 am ]
Post subject:  Re: 2004 XL-7 Radiator Cap - aftermarket options?
murcod wrote:
Further info:

Genuine Suzuki Radiator cap for 2004 model (cap on engine) appears to be 17920-65G50



I just found the receipt from back in 2009 when I purchased one from Suzuki and that is the correct part number.

The modified Tridon is working perfectly, but obviously there are quality control issues for the tabs to require modding. :?
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