Hello all,

Finally pulling my 1986 Savage out of storage after about 10 years. It's been garaged its entire life, has just under 13,000 miles, and is in really nice original condition.

I'm removing the tank, but the gas cap won't open. The key turns normally, but the cap won't release. I've tried pushing down while turning the key and gently warming the cap with a hair dryer, but no luck. I don't want to force it and damage the cap or tank.

Any suggestions before I get more aggressive?

Thanks!

What Verslagen said....likely stuck from crud on the tabs that lock the cap in place.

If you don't have success with the tank upright - then remove the petcock and drain the old fuel out, then turn the tank upside down with the cap over a 5 gallon bucket with the fuel cap pointing down.  Then carefully put some fresh fuel in the petcock hole and try and get the fuel cap submerged.  There will likely be some fuel dripping out the vent in the cap - if you want that to stop install the petcock or block off the petcock mounting hole and the drip will slow down or stop once a vacuum is created in the tank.  Let is soak for a few hours or days and give the key a try.....setting the tank out in the sun to warm up may help speed up the process

Cirj44 wrote on 07/28/26 at 11:57:55:


I would believe that engine heat would help.  Don't try to remove the access cover until after you have gotten the engine running and up to temperature.

When you get it off and put it back on - must make it snug.  It does not have to be really tight - just snug.

there are just some things that need to be replaced when a bike sits that long, I know, I am currently doing the same thing. my bike sat for almost 10 years exactly and there is no part of the bike that does not need to be touched. I would just go ahead and replace the petcock with a yamaha OEM raptor petcock.

As for the crankcase side cover, I use a spark plug gap tool, the round coin style ones, as it fits the slot perfectly and is less likely to strip it than a flat head. Use that with a large adjustable wrench and go slow and easy while pushing in so the spark plug gap tool does not slip. Heat and wd40 help.

Other things you may need to look at are the brakes, the caliper is likely stuck, replace brake fluid for sure, tires, fuel lines, all filters, carburetor, and battery. good Luck.

I didn't replace my crankcase cover with hex, as long as you only snug it up when putting it on then getting it back off is not an issue.

My bike was def a "started right up" situation. I pulled the spark plug and put a dab of motor oil in the piston, then turned it over by hand to make sure it was all loose, replaced with a new spark plug, new gas, and she fired up on the first crank. Smoked a bit until the residual oil burned off then ran like a top.

Seems like you have a good plan, def do the tensioner mod. Good luck.