Stuck Fuel Cap

[Bob_Roller]

Thanks for the pictures, it clears up, whats in there, it looks like most of it is a plastic material, with an aluminum casting .

I don't think the cobalt drill bit will have much difficulty getting through the various layers .

The screw that I have is countersunk, so all I have to do after drilling it, is making a concave dimple in the metal, paint the screw black, and you'll never see it, until you open the hinged part of the cap to refuel .

[bruce_launceston]

Hi Bob, attached is a photo of the top of my fuel cap with no holes or screws, the second photo is the side view showing the hole through which I pinned the cap to lock the top to the thread.
I think that the lock would need to be locked and the pin would go into the lock barrel.

I know this doesn't help get the stuck cap off but if you can get it off somehow it is a lot neater than the screw down through the top.

The photo also shows where the screwdriver marked the underside of the plastic skirt, I think I levered it up to get enough pressure to bind the halves while I unscewed it.

[montmil]

OK. Quandary resolved.

Way back, I had purchased a used replacement fuel cap from Re-Psycled http://re-psycle.com/ after my original cap stopped venting properly and regularly.

The plastic trim ring had a small dent/lift that I looked at for, oh, a nano-second. Bruce's photo and response may have explained it!

Thanks for the photos and ideas, Bruce.

Monte

[the_admiral]

i had this problem,i found that if you put the bike on the centre stand and tie a rope onto the filler cap and over the garage roof truss and tie it off tightly,then just roll the bike off the stand and out she popped

[Lucky_Lou]

My fuelcap was seized the bike had been stood for the best part of 10 years i soaked the thread chamber with plus gas for a couple of days then used a drill with a bit of steel round bar 1/4 inch ish put the drill on hammer and gave the top a good vibration through a protective piece of plastic and off it came.....i describe it as the "Beach boy" effect.
Lou

[Bob_Roller]

Alright, there's a method I hadn't thought of, I've got an air hammer, used for driving rivets, I'll give it a 'whack' and see what happens .

[Bob_Roller]

Went out to the garage, looked for my air hammer, then realized, it's at work .

So I tried a piece of hardwood, and a 5 pound (2 kg) hammer, 5 hits, and success the cap came off, still not willingly .

The not so good news, the inside of the tank appears to be rusted up pretty good .

[montmil]

Bob, Don't forget to slosh out the metal bits from the tank after getting the cap off. Probably needs a bath anyway.

There's still a bit of old fuel in the tank, I'll put some alcohol in there and get the metal shavings out.
This tank does have the metal mesh screen over the inlet tubes of the fuel tap, I'm not getting too concerned, if a few metal shavings are still in there.

Mr. Murphy just entered your garage!  

Monte

[Bob_Roller]

I have to admit, the rust surprised me, due to the dry climate here .

But it doesn't look like it will be difficult to remove .

I sprayed carburetor cleaner into the tank,  the rust, and original red liner came right off, leaving bare metal .