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Arizuno Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Prescott, AZ Gender:	gas cap 10/02/11 at 17:00:05 By far my most embarrassing question to date. Reassembled gas cap after shimming gasket, reinstalled gas cap AND NOW I CAN'T REMOVE IT. Any ideas before I haul it off to a locksmith or M/C mechanic tomorrow?
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arteacher

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Re: gas cap
Reply #1 - 10/02/11 at 17:32:26

One of two things happened:
When you put it back together you did not have the pins that pull the sliding clips in lined up properly. Did you test it after assembly and the pins retracted smoothly? If this is the problem I can't think of a way to fix it, other than drilling out the lock.
You have packed it out too much so those pins are binding. Try pushing down on the top of the cap and turning the key. Don't break the key or you are really screwed.

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ero4444 Full Member Offline weekender Posts: 176	Re: gas cap Reply #2 - 10/02/11 at 17:34:41 geez. Don't drill it out. You didn't change the pins right? Push on the cap while you are turning the lock cylinder. Sounds like the shim is too thick. I don't think you will need a locksmith.
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verslagen1

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Re: gas cap
Reply #3 - 10/02/11 at 17:36:30

arteacher wrote on 10/02/11 at 17:32:26:

If this is the problem I can't think of a way to fix it, other than drilling out the lock.

Arrrgh! NO!

Quote:

You have packed it out too much so those pins are binding. Try pushing down on the top of the cap and turning the key. Don't break the key or you are really screwed.

YES, YES, YES!

Get a friend to help, push down hard. don't collapse the tank Roll Eyes

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arteacher Serious Thumper Offline Ride as if your naked and invisable! Posts: 2581 London ontario Gender:	Re: gas cap Reply #4 - 10/02/11 at 17:45:28 I made a boo boo I did not intend to recommend drilling out the lock, only that I couldn't think of anything else. Very sorry.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: gas cap Reply #5 - 10/02/11 at 18:03:40 drilling is a last resort when all else has failed.
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28642 Tucson Az Gender:	Re: gas cap Reply #6 - 10/02/11 at 18:25:13 verslagen1 wrote on 10/02/11 at 18:03:40: drilling is a last resort when all else has failed. Naaa,... lighting the fuel in tank and blowing the cap off, is the LAST resort... ...
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Fish Full Member Offline Who Shot Who In The What Now? Posts: 213 (near) Tampa, FL Gender:	Re: gas cap Reply #7 - 10/02/11 at 19:06:29 So the drilling and making a spark into the tank would be the 2nd to last resort. Word.
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Boofer

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Re: gas cap
Reply #8 - 10/03/11 at 01:18:38

I've never had a problem with leaks as some have, but it does get hard to turn the key at times. I just get a small tipped oil can and put a DROP of 30wt oil in the key slot, then push the key in and out a few times. Then I put a DROP in the little opening on the side of the cap by the gasket. Then I put a DROP on both of the locking lugs and again work the key several times. All this is done with the cap off. Works for me.

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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: gas cap Reply #9 - 10/03/11 at 01:46:40 If you could turn the key to get it on, you can turn the key if you press the gas cap down hard enough.. but careful not to break the key. I've gotten mine stuck a few times trying to fix the gas cap leak...
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Arizuno Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Prescott, AZ Gender:	Re: gas cap Reply #10 - 10/04/11 at 18:44:45 Thanks, everyone. Taking it to an independent mechanic tomorrow, will attempt to ride with my fingers crossed. Neither muscle nor foul language would release the cap. Can't tell you how pleased I am with myself.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: gas cap Reply #11 - 10/04/11 at 19:04:00 how about a fresh sheet of sand paper. smooth side against the tank, maybe a little grease too. and slowly work it under the rubber seal to grind it away. and work it all the way around.
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Arizuno Full Member Offline SuzukiSavage.com Rocks! Posts: 227 Prescott, AZ Gender:	Re: gas cap Reply #12 - 10/05/11 at 11:47:23 Mechanic couldn't help, and we both think the lock is broken (mea culpa). Tomorrow I'm going to a locksmith, but assuming the worst, does anyone know of a good source for new cap/lock? I'm getting nowhere on Google, and I fear my bike will soon be dry docked for want of a cap. Thanks, amigos.
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SurfJunkie Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: gas cap Reply #13 - 10/05/11 at 12:07:17 Did you ever TEST the lock on the cap PRIOR to re-installing it ? Or did you pull it apart, put it all back together, then blindly stick it back on the bike without a function test ? How hard did you have to press to get the cap on ?
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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: gas cap Reply #14 - 10/06/11 at 07:29:15 I think you can buy plastic gas caps with out a lock, I saw them somewhere, eBay or random google searches...
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