Gas Cap Refurbishment

Little things matter...

Pulled up at the service station a couple of weeks ago, placed the key in the petrol cap and...couldn't budge it. It was a little hard to turn up to that point but the darned thing just wouldn't turn. Embarassing. Had to sit there jiggling the key (it was half way through the 1/4 turn required to open the cap) so I couldn't even extract the key. Perserverance pays off and eventually I unlocked the cap and filled a near empty tank.

Got home and took the cap apart (which I've been meaning to do for a while but...you know...it can wait!) and as I got further into the cap it was becoming obvious that rust was gumming up the works. Cleaned all of the rust residue out, greased lightly all moving parts plus a bit extra for water protection, and put it all back together - easy job, about an hour and a half well spent. Watch out for the tiny springs on the sliding lock mechanism if you do this job.

The cap now works smoothly, like new. If your gas cap is feeling it's age and it is a bit stiff to turn the key I recommend this minor surgery. Now going to the gas station won't be such an embarasing expeience.

 

i cant fill my tank all the way. cuz if do, when go to leave there will be gas running down the tank and my leg. the seal is good but it comes out the screw hole. don't know why yet. the p.o. replaced it at one time. least i assume since the tank key dont unlock the power lock or the helmet lock. but least the key turns easy though.

 

Do not fill the tank all the way to the neck! The gas cap is made to vent incase the gas expands...and it will in hot weather (ask me, I found out the hard way)
I filled my tank to the neck and rode the bike home (about a mile) and after I parked it, the gas ran out the gas cap from it expanding. Now I don't fill it to the top anymore!