GT-series gas cap disassembly & reassembly

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jabcb
Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
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Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

GT-series gas cap disassembly & reassembly

Post by jabcb »

One of my gas caps doesn't close enough to get a good seal. Its loose when closed & locked.
The bike was rekeyed by a PO. Based on the scratches on the underside of the gas gap, it looks like the PO had the gas gap apart.
The latch doesn't close as far as any other of my gas caps, which is undoubtedly the problem.
Also doesn't close as freely or pop open like the other gas caps.

So I am presuming the gas cap can be reassembled incorrectly, and this is my problem.

Is there a "correct" way to disassemble & reassemble the gas cap?

When locked, my cap looks like this:
BadGasCap.jpg
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BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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oldjapanesebikes
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Suzuki 2-Strokes: GT750(Jx3,L,M,A,B),T500
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Re: GT-series gas cap disassembly & reassembly

Post by oldjapanesebikes »

I admit I've never seen any 'step by step' guide on this topic - when I've done it myself, there were a couple of ways things could go back together. I wrote about it here and also posted this photo on this board and my own site. Not sure it it helps, but the problems are usually with the assembly of the spring barrel (#6) and the alignment of the #3 with the release button #4 - assembled one way gives a loose fit as you describe - rotate the shaft (#3) and it fits together properly. This is an earlier style in the photo with no key, but the later ones are similar. 8)

Image
Ian

If at first you don't succeed, just get a bigger hammer !
User avatar
jabcb
Moto GP
Posts: 4311
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: GT-series gas cap disassembly & reassembly

Post by jabcb »

Thanks for the info. Should be able to figure this out now.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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