Too tight gas cap
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  1. #1
    Junior Member Topo's Avatar
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    Is there something I should put on the gasket? Most of the time, it's super hard to turn....almost to the point of wondering if I'll be able to get it on or off.

  2. #2
    Senior Member lizrdbrth's Avatar
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    I smear a bit of engine oil on the gasket from time to time.



    The other thing to check are the cams inside thae upper surface of the tank. Heavy-handed pushing on the cap can crush the tank opening in a bit over time. This will be difficult to see but if you lay a straight edge over the tank gasket sealing area of the tank you'll probably see a miniscule amount daylight under the inner radius of the opening.



    This is easily corrected by using a long screwdriver with the shank wrapped in tape and gently working any off-level portions of the cams until the cap fits snugly, but not overly tight.



    I can explain it to you, but I can't understand it for you.

    Powdercoated '87 frame, extended swingarm, YZ fork legs, ATV tire, 14/55, XT350 tank, spliced quick-release seat, disc brake conversion, beeg headlight, beeger rack, Lizrdcooler, Lizrdventz and bunch of other stuff all covered in invisible ink.

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  3. #3
    Senior Member Dark Sol's Avatar
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    Man don't get me started on how bogus the tank cap is. Even if I put something on it to let it slide easier, by the next fill up it's completely dried and tight again. I've hurt the hell out of my hand turning that damn thing and a few times I almost gave up trying to get it off.



    BS! why don't they use a hinged tank like every other bike I have had.
    2008 CRF230L

    2006 CBR1000RR

    2007 CB919 - 70k Miles and still runs like new!

    * 2001 TW200 (Sold after 15k miles of fun)

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  5. #4
    Senior Member lizrdbrth's Avatar
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    Just don't be ham fisted when you straighten it. I've found most are tweeked in the manner I described above.



    I can explain it to you, but I can't understand it for you.

    Powdercoated '87 frame, extended swingarm, YZ fork legs, ATV tire, 14/55, XT350 tank, spliced quick-release seat, disc brake conversion, beeg headlight, beeger rack, Lizrdcooler, Lizrdventz and bunch of other stuff all covered in invisible ink.

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  6. #5
    Senior Member RodneyReed's Avatar
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    I haven't had any trouble with my TW gas cap, but I have a KTM bike that can be a real pain. I've discovered a trick that is a bit silly, but works as long as there is a little gas in the tank. I shake the bike up and down so that gas splashes on the bottom of the cap, then it twists off with ease. I'm going to try the engine oil as lizrdbrth mentioned, my fear is that it will get washed way by the gas, but maybe it will soak into the rubber gasket somewhat?

  7. #6
    Senior Member lizrdbrth's Avatar
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    Quote Originally Posted by Rodney View Post
    I haven't had any trouble with my TW gas cap, but I have a KTM bike that can be a real pain. I've discovered a trick that is a bit silly, but works as long as there is a little gas in the tank. I shake the bike up and down so that gas splashes on the bottom of the cap, then it twists off with ease. I'm going to try the engine oil as lizrdbrth mentioned, my fear is that it will get washed way by the gas, but maybe it will soak into the rubber gasket somewhat?


    It will eventually. To beat a dead horse, a tight cap is often the indication that your flange is tweeked. Worth a look. I've re-tweeked mine several times in the last couple of years.



    I can explain it to you, but I can't understand it for you.

    Powdercoated '87 frame, extended swingarm, YZ fork legs, ATV tire, 14/55, XT350 tank, spliced quick-release seat, disc brake conversion, beeg headlight, beeger rack, Lizrdcooler, Lizrdventz and bunch of other stuff all covered in invisible ink.

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  8. #7
    Senior Member darnold87's Avatar
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    I use bearing grease on both surfaces (tank and cap)... seems to work great for 3months or so... then it starts getting tight again...
    ~Davey

    '89 TW200

    '94 Suzuki Sidekick

  9. #8
    Senior Member peruano's Avatar
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    Okay, I'll get on my gas (soap) cap box again. Mine was tight when I had the stock cap (and because it had a key sticking out of the middle of it, it was even harder to get a good grip on. I was always conscious that I might break off the key just trying to twist the cap off. I used grease, oil, gas, and everything but toe jam to try to lube it - and all would work for a fill or two and then it would get difficult to remove. I finally resorted to a nonlocking Yamaha cap which I can get ahold of if needed, and which I have never had problems with it being as tight. I have never tried bending the flanges but that should help. Tom
    Tom - TW200 2002, Kawasaki VN 500 2006

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  10. #9
    Senior Member elime's Avatar
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    Quote Originally Posted by darnold87 View Post
    I use bearing grease on both surfaces (tank and cap)... seems to work great for 3months or so... then it starts getting tight again...




    Ditto!
    Long live the internal combustion engine!

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