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1Back to top Go down   Fuel tank cap - rekeying and repair Empty Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 12:08 am

88

88
Life time member
Life time member
My temporary solution was so effective it took 6 months to get around to this..Having assembled the bits I finally got around to it today.

Most tank locks fail when the little nibs on the lock barrell get corroded and break down. The corroded barrell then chews the holes in the plastic receiver cup leading to the barrell just spinning without activating the latch. The pictures below show the old versus the new barrell and the new plastic cup.

Fuel tank cap - rekeying and repair Img_0910

Fuel tank cap - rekeying and repair Img_0911 RE

Ok so getting at the parts....

with the tank open and the opening covered in case of dropped parts ....(if you have to force or drill the old lock out don't worry things cannot get through to the tank with the cap closed.) remove the 3 screws and carefully withdraw the plastic cover..

Fuel tank cap - rekeying and repair Img_0912

there are two springs in there, one like a biro spring which can fly so take care.

Next remove the barrel it is held in by the last tang (you need the key in the lock) push the tang in with a flat blade screwdriver and remove the barrell.

I did get keys with the replacement lock from motobins but I wanted it on the original key. The simple way to rekey it is to stick in your ignition key and file off any tangs that stick proud of the barrel. Be careful not to file the last one. A bench grinder makes this super easy but the tangs are brass and soft so it's a quick job.

Once your happy, press in the last tang (with the key in the lock) and insert it in the cap. When it's properly seated it should look like this...

Fuel tank cap - rekeying and repair Img_0913

next you need to replace the retrun spring in the cover, then the receiver cup, the latch plate and the biro like push spring that keeps the latch pushed out. It should look like this .....

Fuel tank cap - rekeying and repair Img_0914

There is a spring behind the cup that I omitted to photograph but where it goes (in grooves) is quite apparent.

At this stage you need to screw it all back together and test carefully. I found that testing it with just hand pressure instead of the screws didn't work.

There is surprisingly little movement in the latch but make doubly sure you are happy with everything before closing the cap.

I must say a big thanks to MotoSmith who sent me the plastic cup from California. I don't know the part number for that. Maybe one of the members who is good at finding them will post it up.

88KE


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Fuel tank cap - rekeying and repair Ir-log11 88....May contain nuts!Fuel tank cap - rekeying and repair Ir-log11

"The world is a book and those who do not travel read only one page." - St. Augustine from 1600 years ago & still true!

Bike: K100LT 1988. 0172363. AKA the Bullion Brick! Mods: k1100 screen and stands.
K1: 1990. 6374189. Custom Stealth Black paint.
    

2Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 12:16 am

Inge K.

Inge K.
VIP
VIP
88KE wrote:I must say a big thanks to MotoSmith who sent me the plastic cup from California. I don't know the part number for that. Maybe one of the members who is good at finding them will post it up.

It`not sold as a single part, you have to buy a complete filler cap.


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

3Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 12:40 am

88

88
Life time member
Life time member
That's a shame because the complete cap is not cheap and the job is straightforward.

See your friendly wreckers I guess!



88


__________________________________________________
Fuel tank cap - rekeying and repair Ir-log11 88....May contain nuts!Fuel tank cap - rekeying and repair Ir-log11

"The world is a book and those who do not travel read only one page." - St. Augustine from 1600 years ago & still true!

Bike: K100LT 1988. 0172363. AKA the Bullion Brick! Mods: k1100 screen and stands.
K1: 1990. 6374189. Custom Stealth Black paint.
    

4Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 1:45 am

charlie99

charlie99
VIP
VIP
good process and descriptions 88

thanks from many of us ..


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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OFuel tank cap - rekeying and repair Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

5Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 1:56 am

Inge K.

Inge K.
VIP
VIP
Another fix for the problem with the plastic cup is to be found here .


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

6Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 8:28 am

Crazy Frog

Crazy Frog
admin
admin
Very Happy Very Happy

This would be a minor issue with the new bike. It has an 11 gallons auxiliary fuel cell in the sidecar and I would just have to turn ON the transfer pump.
Sorry, the rig won't be delivered for another week but I am already bragging about it.

CF


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Fuel tank cap - rekeying and repair Frog15Fuel tank cap - rekeying and repair Logo2101986 k75, 1985 K100rt, 1985 K100rt/EML GT2 sidecar, 1999 K1200lt/Hannigan Astro Sport sidecar.
    

7Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Mon Sep 17, 2012 9:27 pm

sidecar paul

sidecar paul
Life time member
Life time member
Good one 88 & motosmith.This forum never ceases to amaze.

When I had my cap apart, a bit of grease on the sliding parts improved the action no end.

An extra 11 gallons, you lucky %$^&* CF! (Can't find an emotion for jealous.)

Paul.


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'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

8Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Tue Sep 18, 2012 2:32 am

Crazy Frog

Crazy Frog
admin
admin
@sidecar paul wrote:

An extra 11 gallons, you lucky %$^&* CF! (Can't find an emotion for jealous.)

Paul.

Razz

I am so excited about getting the new bike.
I bought it without seeing it as I totally trust my fellows BMW riders.
This is what I wanted and after waiting patiently for almost 10 years, I found it.
I have to admit that the owner of the rig registered on this forum about a month ago.
During a private conversation, he expressed his intention of selling his bike. I told him that I was very interested but he didn`t think that I was serious.
After multiple Emails, we learned to know a bit about each others, and even if he`s sad about selling the rig, he`s happy knowing that his baby will be in good hands.

CF


__________________________________________________
Fuel tank cap - rekeying and repair Frog15Fuel tank cap - rekeying and repair Logo2101986 k75, 1985 K100rt, 1985 K100rt/EML GT2 sidecar, 1999 K1200lt/Hannigan Astro Sport sidecar.
    

9Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Thu Aug 28, 2014 6:30 am

Shep

Shep
Silver member
Silver member
I know this is an old post but it is the closest one to discuss my current issue with reassembling a gas cap.

I also watched Chris Harris (You-tube) and it seems he tensioned the small spring under the receiver cup with the receiver cup  before he replaced the latch and spring. I have had difficulty doing what Chris Harris did (need three or forur hands).
I then looked at page two of Inge's post and will go back to that orientation. However the key and latch did not have the same snap when I did it that way. My other K bike has an extremely positive spring return when the key and latch are operated.
S


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Model        Production Date/Serial Number
K100RS      1984 July/ (F0040448)
K100RS      1986 Dec/ (H0142581)
    

10Back to top Go down   Fuel tank cap - rekeying and repair Empty Re: Fuel tank cap - rekeying and repair on Thu Aug 28, 2014 10:48 pm

Shep

Shep
Silver member
Silver member
Okay so I figured out how to get the positive spring return when you turn the key to open the latch and I didn't need three hands.

My next question is regarding the plastic nose piece:
Fuel tank cap - rekeying and repair Z
What is its function? When I tried to pop it on an old fuel cap I broke one of the tangs and it was just empty inside.

On the fuel cap I just put back together there appears to be something whitish inside but I don't want to try to pop it open when there is no reason to do so.

Thanks

S


__________________________________________________
Model        Production Date/Serial Number
K100RS      1984 July/ (F0040448)
K100RS      1986 Dec/ (H0142581)
    

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