RE: Gas cap won't latch - 6

I as still thinking what to do. I have a full tank of fuel and can keep the cap closed with aluminum tape while it is in my garage. I will continue to try to move the plunger and reinsert the pin, but I am getting tired of smelling gasoline while working on the cap. I just have a bad feeling that the pin is bent or otherwise damaged and there will be no way to straighten it out if that is the case. If I could figure out how to do it, I would pull the pin out, but so far I can't get enough of a grip on the pin to try that.

your cap is on the left Richard mine is on the right (green and red) the red arrow shows how much plunger is out compared to yours. my locking pin is on the other side of the plunger's hump.
duel.jpg - Bild entfernt (keine Rechte)

When unlocked by your key the pin blocking your plunger movement should drop (or able to be pushed down slightly)

the pin needs to go down i think... yours is locking the movement of the plunger...

Zitat von JohnnyRockett im Beitrag #77

---

your cap is on the left Richard mine is on the right (green and red) the red arrow shows how much plunger is out compared to yours. my locking pin is on the other side of the plunger's hump.


When unlocked by your key the pin blocking your plunger movement should drop (or able to be pushed down slightly)

---

Zitat von JohnnyRockett im Beitrag #78

---

the pin needs to go down i think... yours is locking the movement of the plunger...

---

Good luck with your quest Richard..... using the tip of a very small screwdriver, whilst the cap is electrically active (in unlocked mode) , press down on the locking/guide pin with the screwdriver whist simultaneously applying rearward pressure on the slide plunger with needle nose pliers (a generous application of penetration oil should help) .

My bike uses a key, so only commenting from distance. First of all I would test the actuator and power supply for the locking mechanism.

I would then work out exactly how the system should work and what does the pin in question actually do? On a bike that is functioning correctly does the lock actuate to unlock but closed on power on? Does this bike try to? (any noise from the lock)

If the pin was not there would the cap close securely but just not lock on power off or does it prevent lock actuation?

If the actuator can be made to work without the pin then maybe a switch could be inserted into the wiring. That would be the cheapest solution, but a bodge.

Looking at the pictures of the one on eBay, it looks to be simply switched / actuated so doesn't look like it needs pairing. If it was me (and electrics were OK) I would buy it, fit it, and repair the original at my leisure so that when the new (to you) one fails you have a spare waiting. A few hours work to replace. Jewellers and watch makers can make small replacement parts for reasonable cost

Until the last few pictures from Richard I did not realize the notch in the plunger for the pin goes clear through. I had to get my head down low to see it on my bake.

Success! The cap lock is working again! All I did was to turn on the ignition and was able to move the plunger easily into place with my finger. Then the pin popped into its hole. I was then able to turn off the ignition and after 90 seconds I was able to close and lock the cap. It stayed locked until I turned on the ignition again and then I turned it off, the cap lock released and when I pushed it down again it locked. You can bet that from now on I will be lifting the locking tab on the cap while gently pushing the cap down after filling the tank. I just wish I knew what caused the problem in the first place.

I have no idea why I wasn't able to do this earlier. I guess I was just trying to move the plunger in the wrong sequence. Either that or the conjunction of Jupiter and Saturn for the first time in 800 years fixed the problem.

And in the process of turning my ignition on and off, I was informed by my dash that I needed to replace the battery in my fob.

And here I was looking forward to bashing the parts with a big hammer and drift.

Phew!! Great result and great help from JohnnyRockett.

It was definitely more drama than I needed during the holidays. And thanks for everyone's help and support, too. You are a really great community. I am just sorry that I can't contribute as many useful posts as do others. My skills center mostly around cutting and pasting jokes, rather than solving technical problems with the RS.

Have a merry Christmas and a happy New Year!

That's great.
Maybe the cleaner lube finally did it's job.

Zitat von Richard230 im Beitrag #84

---

And here I was looking forward to bashing the parts with a big hammer and drift.

---

Zitat von Richard230 im Beitrag #86

---

It was definitely more drama than I needed during the holidays. And thanks for everyone's help and support, too. You are a really great community. I am just sorry that I can't contribute as many useful posts as do others. My skills center mostly around cutting and pasting jokes, rather than solving technical problems with the RS.

Have a merry Christmas and a happy New Year!

---

I'm disappointed you got it fixed...
It'll be back to windscreens and seats now.

Alan