Need some emergency help - Gas cap will not go back on the tank - Rain coming!

[kharper4289]

Took my gas cap apart to help a vacuum issue with the fuel delivery.  I put it back together just how it was before and it WILL NOT seat into the tank.  I put the 4 tank allen bolts back in and it will not close, no fiddling with the key will make it work.

I think the gasket is blocking the closure.

http://imgur.com/a/lETQP

There is my cap, anyone have any ideas?!

[Al Capwn]

Does the mechanism retract at all when using the key? Which part does not seat? The main "ring" where the bolts go, or the inner cap portion?

[kharper4289]

I'm not sure.  The mechanism retracts fine, it works fine, better than before.

It's getting hung up on the black O-ring/seal I believe.  I'm not sure how, or why.  I assembled it just as I disassembled it, and now it will not shut.

Infinitely frustrating.  I've put it back together three times and it will not shut!  It gets close, but then it won't GO.

[ShowBizWolf]

Idk if you have seen this thread but it's the one that came to mind when I read your post...

http://gstwins.com/gsboard/index.php?topic=41061.0

Maybe it will help? It has helped others in the past and it is quite detailed... I hope you get it figured out !!

[kharper4289]

That's the thread I followed.  Well I tried.  That tank cap is absolutely nothing like mine and the thread didn't help at all


http://www.r6-forum.com/forums/showthread.php?t=141698


This thread  is exactly my problem and he did not find a solution, of course.

[ShowBizWolf]

Fiddlesticks    I hope someone will have the answer...

[kharper4289]

Fiddlesticks    I hope someone will have the answer...

The guy I bought this bike from said it would be great to learn basic maintenance on.  He didn't tell me the bike would just be under maintenance all of the time and I'd never get a chance to ride it.

[ShowBizWolf]

Oh no don't lose hope... these bikes are awesome and hopefully others will back me up on this in order to encourage ya... sounds like this one issue is really giving you a hard time and I can understand how it would be discouraging. I wish I could be of more help, hang in there !!

[kharper4289]

I ordered a new cap assembly, unfortunately it is fresh from China and will be here in a hasty 2-3 weeks.

Ugh.

[fetor56]

With anything like this(disassembling carbs,wiring,etc) use your phone camera or any camera to take progress pics as u go along.
I suspect you've done something wrong in reassembly otherwise it would fit.Try your local ebay for a 2nd hand cap while your waiting for that chinese copy...local,genuine,will be better quality anyway.

[kharper4289]

I did that.  I took pics of every process.  I put it back together exactly how it came apart.  I cannot fathom what is wrong.  It's like it isn't lined up on the tank properly when it is bolted in.  With the way the cap is designed, there is very little room for error, all springs are accounted for, etc.

I seriously don't get it.

[metatron]

Best bet is to strip it right down and put it back together again, probably just put something back in the wrong order.

[Slack]

Were you putting it on the tank backwards?

[kharper4289]

I wish it were that simple

Can you guys post some pictures of yours so I can check my work?

[HPP8140]

I remember this issue and I believe the trick is that the cap has to be open when you place it back on the tank.

[Watcher]

Try leaving the bolts loose, closing the cap, then tightening the bolts.

It could simply be a case that when the bolts are tight it is shifting the assembly off center and then it won't close no matter what you do.  It has to be fairly perfect to work.

[kharper4289]

Tried it.

I discovered the problem but I can't fix it.  There is a washer missing from my final assembly.  The weird thing is... I did the work on a white sheet in a small space, there's no way a bigass washer got away from my assembly, yet it is in fact gone.

Oh well, over-nighted a new keyless cap.  Life goes on.