GT500 Gas Cap Doesn't Seal

[BLAZY]

I'm repairing my 76 GT500 gas tank--derusting, POR-15, petcock cleanup and vacuum bypass modification, etc.

The fuel cap won't snap down flush with the filler neck, even when I apply enough pressure to "oil can" the metal on the top of the tank. The latch mechanism clicks open and shut fine, but the back of the cap sits about 1/8" above the rim of the neck when it's in the "latch" position.

I have a new cap gasket and have fitted it both sides up with no change.

Any ideas?

[jabcb]

Have that problem with one of my gas caps.
The bike was rekeyed by the PO & the gas cap wasn't assembled correctly.
See pic in this thread: viewtopic.php?f=9&t=8742&p=131994&hilit ... ly#p131994

[BLAZY]

This is helpful. Thanks.

To the Batworkbench, Robin!

[tz375]

Is it possible to purchase a new lock set for a cap or does it have to be re-keyed or replaced with a complete new cap?

[jabcb]

The gas cap can be disassembled, but I'm not exactly sure how. I used a gas cap off of a project bike.
The underside of my gas gap was marked up from someone having done that.

I've never seen anything that would suggest that Suzuki sold replacement lock cylinders.