RE: Gas cap won't latch - 5

Zitat von Mr. 36654 im Beitrag #60

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Zitat von Richard230 im Beitrag #46

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Zitat von Lee im Beitrag #42

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Zitat von Richard230 im Beitrag #40

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I don't know what the vertical pin does, but mine does not stick up through the hole in the plunger. I really wish I knew exactly how the cap keyless locking mechanism functioned. I can't figure out what the vertical pin does, but I suspect whatever it does,

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I also would like to know what the vertical pin does.
On both of our bikes the pin does not always stick up. On our bikes the cap works ok even when the pin is not raised.
I started to pay attention to that pin after we had trouble with Debbie's cap not opening.

I mentioned to the service manager at Kansas City about the pin not always being in the raised position and he said it didn't matter.

I think her plunger was gummed up. After spraying it with WD 40 several times it took two days for the cap to work normally.
When her cap would not open she would cycle the switch on and off or raise the tab several times.
Her hearing is better than mine. She would listen for a click before fully lifting the tab.

I don't think any of this will help you but it might help others when the cap refuses to open.

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But if it doesn't make any difference if the pin has not raised into the hole in the plunger, than what possible purpose could it be useful for?

I think what I will try next is some Mouse Milk lubricant. A friend who owns an airplane gave me a little of that very expensive lube. He claims that it is the best penetrating lubricant available. I tried it once on a water spigot handle that wouldn't move and it loosened up immediately.

I am going to pass on that eBay fuel cap assembly. Just installing it on the fuel tank would be a challenge for me. If I can't fix the problem by the weekend, I still plan to break off the plunger, or ram it back into the mechanism with a hammer and drift so that it is not obstructing the closing of the cap. It looks to me like the cap should close and latch just fine once that plunger is out of the way and I really don't need a locking gas cap, just one that opens and closes.

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OK, being serious for a change, why not "probe" the hole with a bent paperclip or similar to depress the fouled/stuck pin?

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Zitat von Richard230 im Beitrag #54

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According to my BMW service DVD it looks like I would have to remove the upper half of the bike to get to the top of the fuel tank and then detach the filler assembly from the fuel tank. That is just too much work for me, especially as I don't know that would actually fix the problem.

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Richard do you have a shop you can call and talk to a Tech or a knowledgeable service manager.
Explain what you have tried so far and ask if they have any suggestions.

On the GS forum lots of members reported this problem.... the solution was simply slide the plunger back to allow the cap locking tab to engage.


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Zitat von Lee im Beitrag #63

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Richard do you have a shop you can call and talk to a Tech or a knowledgeable service manager.
Explain what you have tried so far and ask if they have any suggestions.

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Zitat von JohnnyRockett im Beitrag #64

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On the GS forum lots of members reported this problem.... the solution was simply slide the plunger back to allow the cap locking tab to engage.

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Zitat von JohnnyRockett im Beitrag #64

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On the GS forum lots of members reported this problem.... the solution was simply slide the plunger back to allow the cap locking tab to engage.

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In that case I have to think the plunger is seized and his suggestion of penetrating fluid my free it up... it seems the most logical conclusion... plunger seized in incorrect position.

Here is a photo that best shows the mis-aligned pin that is blocking movement of the plunger. I just can't figure out how to get it back into the hole in the plunger. Nothing I have tried yet has worked. I really wish I knew what caused the pin to loose its grip on the plunger. Perhaps it was me forcing the cap down too hard? The plunger will move back and forward, it is just blocked from its complete stroke by the pin.

IMG_9710.JPG - Bild entfernt (keine Rechte)

Wenn Sie hier auf Links zu eBay klicken und einen Kauf tätigen, kann dies dazu führen, dass diese Website eine Provision erhält.

This is definitely the issue....the plunger (horizontal) slides over the top of the pin and the pin (vertical) ... gets hidden by the plunger
you can see the pin hiding under the plunger in your picture arrowed yellow here. perhaps the pin is bent slightly.

pin.jpg - Bild entfernt (keine Rechte)

if this does not work there is another cap for sale for £50 from an Eastern European Bike Dismantlers...

Werbung: https://www.ebay.co.uk/itm/BMW-R-1200-R-...de/163123014410

or perhaps the constant pressure of the cap banging down on the misaligned plunger has pushed it down too hard in its slot and has jammed it ... will it lift slightly in its furrow to enable it to slide to the correct position, perhaps with a pair of pliers?

If this does work.. the fact it has jammed open would concern me that it might jam closed... and would replace with a different one.

Very interesting thread. Do we know what the purpose of the pin is?

Zitat von Richard230 im Beitrag #69

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Here is a photo that best shows the mis-aligned pin that is blocking movement of the plunger.

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I think the pin is a guide for the horizontal sliding plunger

Ok from looking closely at my fuel cap... I think I know what's wrong. ..

The pin comes up behind the plunger like it is now in Richard's post, when it is LOCKED- this will prevent the cap from clicking down.
The pin drops when unlocked by the bike having the key in range,
this then allows the plunger to slide back towards the rear of the bike and the cap can then open.

Your plunger is in the locked position.
we have to discover if by taking the steering lock off will allow the plunger to move.. this unlocks my cap on my machine. if it does the plunger should be able to slide back into the rearward open position. allowing the cap to close.

if the plunger is damaged in some way or seized due to grit.. it may not move.
If the pin is servo operated.. a blown fuse or damage servo will mean it will not move.
the locking mechanism must use a servo motor... which if the locking pin is jammed might trip out.
Check your fuse box to see if you have a blown fuse.

This is my best guess.

JR