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Stuck fuel tank filler cap

Phil R

Registered User
Anyone else had this problem? Fuel cap won't disengage fully, such that you can't get petrol in, which is something of a handicap.
I first had this problem a couple of years ago, it went away after I lubricated something or other (I think), but now it's reappeared.
My workaround then and now was to loosen the hex bolts attaching the filler cap to the tank, which gets enough wriggle room for it to open which allows for refuelling and such other helpful things as trying to fix it properly.
No obvious trace of anyone having this issue on here as far as I can see. I have found these two links, which appear to offer a lasting solution but it seems a bit brutal:

http://www.vfrdiscussion.com/index.php?/forums/topic/72538-gas-cap-issue/

https://www.youtube.com/watch?v=_iFP9tC62bQ

Would be interested if anyone has has this issue and on what causes it (is it simply a lubrication issue?) and whether anybody has tried this fix.
2002 Bird fwiw.
Cheers,
Phil
 

andyBeaker

Moderator
Staff member
Moderator
Club Sponsor
Try giving everything a really good clean and then lubricate everything with graphite powder. Give the key a good coating and lock and unlock the barrel many times.

The problem with a lot of 'wet' lubricants is that they can dry up and/or attract dirt. Many a lock has been abused by WD40 over the years.

Might work, might not.
 

DEG5Y

Been there, and had one
Club Sponsor
Similar but my problem was after fuelling I had to fanny about to get it to re-lock.
Put a squirt of acf in it when I got home, we'll find out if it was successful next time round.
 

firephil

Registered User
Fuel filer woe!

Hi,
Just a thought ...many moons ago after a attempted theft I had to change the cap to a cheap one from (ahem) overseas!
Bad move as I had to prise it open with a small flat blade screwdriver whenever I needed to fuel up!

Bit the bullet and bought genuine from a breaker,end of problems.
Q.is yours a gen part?
Cheers.
 

CBRDEAN0

Registered User
I helped a mate fit a new aftermarket lock set to his BB.

The fuel cap kept sticking as you describe and as Firephil describes.

The front edge of the aftermarket filler caps has a small lip on it that causes this issue.
Took the cap off - Two minutes with a file and re fitted it. No more problems.

You can see the lip on the pic below.

motorcycle-cnc-tank-cover-fuel-gas-cap-cover-fuel-tank-cap-with-keys-for-honda-cbr400-250-600-vtr250-cbr1100xx-moto-accessories.jpg
 

Pugwash

Been there, and had one
Club Sponsor
I've broken a key in mine before. Luckily I had the spare on my key-ring to start the bike again. After that I also squirted acf into the lock, as it was the barrel sticking, not the latches.
 

Phil R

Registered User
Lock is the original that was on the bike.
Thanks Pugwash.. I think when I had the problem before I stuck some graphite oil in the lock and around the mechanism which seemed to help sort it, unless it was that and a freakish combo with loosening and tightening the bolts releasing something. Have just got some fresh ACF50 from Jaws so will give that a whirl.
The approach of filing off a bit seemed to be rather not as Mr Honda intended!
 

DLN1965

Moderator
Staff member
Moderator
Club Sponsor
The penny just dropped .....

Fuel cap lock issue ...

Original poster is Phil R (Up?) 8rfl@

Ohhhhh It wasn't a joke ???9:dunno:
 

Phil R

Registered User
No, no puns dln... brok3

Interim update, stuck some ACF50 in the lock, no joy.
Followed it up with a smothering of same round the visible movey bits on the underside of the filler cap, and it opened OK. Can be temperamental though so maybe just a fluke. So, no need to set to with a metal file or whatever just yet. But I shall continue to carry a suitably sized Allen key around with me just in case I need some petrol. @tu*
 

Squag1

Can't remember....
Club Sponsor
As far as I know you shouldn't put oil in such a lock.
Graphite powder. Lead from a pencil. I used to have lots
in the good old days of clutch pencils.
Now I use a soft pencil and a nail file to make graphite.
Works a dream.
 
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