| Author | Message | ||
     Milesvdustin |
Hey, I just got back from Iraq last night, and Lo and Behold, My gas cap is stuck this morning! Its a 98 S1. So how the heck do I get this thing off there? And once its off, how do I keep it from happening again? Thanks! | ||
| Mick |
give it a squirt of CRC or WD40 , the seals probably stuck. | ||
| Mmmi_grad |
Welcome back home brotha. | ||
| Dfbutler |
the shaft that retracts the pawls that lock the cap is plastic and strips. You'll need your key code to order a new cap and remove the screws that hold the cap to get it off. | ||
| Littlebuggles |
If it's been parked for 15 months or so it probably isn't stripped, try Micks suggestion and squirt the lube of choice in the fliptab, and maybe around the cap - in case gaskets are dried up and glued in place. Welcome back and thanks for your service! | ||
| Littlebuggles |
Oh yeah, the lube should keep it from happening for a year or so, unless it is stripped out or getting that way... I really like tri-flow, doesn't seem to get as sticky as wd40 and the teflon stays around after the lube dries up. | ||
| Milesvdustin |
I dont have the locking gas cap, just a flip tab with BUELL in small black letters on it that comes up. It seems like the front is stuck, the back will come up somewhat. I really want the damn thing outta there! So if I spray some lube inside the working parts in the bottom it should come free? I will give it a go. Also, I need a new battery. What should I go with? Thanks again! | ||
| Oldog |
WELCOME HOME AND THANKS!  | ||
| Ratbuell |
Just pull, curse, yank, and pry...it'll come off. Once it's off (I've had this happen on both my S1W and my S2), flip it over and look at the inside. You'll see the black plastic piece that rotates to 'lock' it down to the tank, it has 2 large tabs, one on each side. On my bikes, those plastic tabs had swollen (swear to god) enough they were getting caught on the ring on the tank, refusing to let me gas up. I took a file to one (at the pump, had a file on my Gerber) and a Dremel to the other. They swelled in diameter, so I took some material off the outside edge, slipping/fitting after each round of grinding. | ||
| Milesvdustin |
Thanks for the welcome everyone, its nice to be home! Im going to go mess with it now. Anyone know what battery these things take? | ||
| Sparky |
What happens too is the rubber "slosh plate" of the tank that the cap innerds fits into can shrink over time, making for a slight interference fit that makes it difficult to remove the cap. If this is the case, the fix is to take a sharp X-Acto knife and trim about a 1/16" off the inside diameter of the rubber piece. After doing this, the edge of the slosh plate won't catch on the cap, making for easy cap removal. | ||
| Buellerthanyou |
Dustin, has yours had the battery tray conversion done? It converts the original tall vertical battery to a standard HD 65948-00 (which is what is spec'd for them now). If not, there is a kit, part number Z0022.9, that does the conversion and also contains the battery. HellBuelly J P.S. Welcome back home! | ||
| Skntpig |
http://www.badweatherbikers.com/buell/messages/476 23/387145.html?1219321159 | ||
| Thatdudejoe |
That's funny, my 98 S1 does the EXACT same thing. I just shimmy it out of there when at the pump at the expense of my fingertips! | ||
| Milesvdustin |
The back of the cap will lift up, but the front seems to be jammed in there real good! I don't know if my battery has a different tray, it has a strap around the side of it and its a Delka powersport battery. H-D tried to sell me a new battery for 220 bucks, No thanks! I did get a new rear tire from them, a Dunlop Sportmax or something like that. And they did not adjust my belt too tight! At least one of the mechanics knew a good bit about the S1, so I was pretty happy about that. Can I take off the screws around the cap to get the dang thing out? | ||
| Oldog |
I would try the wiggle and jiggle method, I have had a similar issue lately Try tightening the screws in the ring just a little and see if that helps, if you get it out check where the stem and the black plastic locking collar are assembled mine is not loose, so it must be the rubber part is swelling or the plastic is swelling. I split the rubber curtain thing most of the way up at both ends (Message edited by oldog on September 09, 2008) | ||
| Blks1l |
I have a Yuasa YTX12BS in my S1 with the original tray. It is one of the AGM batteries, and sits on it's side. Add the acid to the battery, and let it sit upright a day or so, to prevent leakage before it is all absorbed. Dean | ||
| Buellerthanyou |
Dustin, as Dean said, there are several batteries out there that will work if stood on their side. The "battery" that your Buell shop tried to sell you is actually the kit, part number Z0022.9, that does the conversion and also contains the battery, that I posted up above. Here's a breakdown of the kit: AA0404.1CZ SCREW, CAP, 1/4-20 X 1/2 1 Y AA0406.2CXBL SCREW, 1/4-20X3/4 BZ, GR8, SHCS, 2510N 2 Y BA0408.4Z STARWASHER, ZINC, 1/4 X 1/2 4 Y B0613.1Z WASHER, 6MM X 13MM STD, ZINC 2 Y DA0400.1FZ NUT, 1/4-28, STD., ZINC 1 Y DA0400.10CZ NUT, 1/4-20, SPRING LOCK, ZINC 1 Y -J01992 INSTRUCTION SHEET 1 N DA0400.2FZ LOCKNUT, 1/4-28, HEX NYLOCK, ZINC 1 Y L0001.9 BATTERY PAD, TRAY SIDE 1 Y L0002.9 BATTERY PAD INSERT(LONG) 1 Y L2120.9 INSERT, BATTERY TRAY 1 Y + Y0123.9 STRAP, BATTERY 1 Y Y0303.2B WIRE TIE, BLACK (5/31 W X 8.5" LONG) 2 Y + 65948-00 BATTERY, AGM 1 Y MOSTLY a battery, but a lot of other parts as well, because to use the current H-D battery requires moving the voltage regulator and modifying the battery tray. I know all this 'cause I've got this very kit sitting on a shelf at work, waiting for me to fork over the dough! In the meantime, I have the wrong battery, sitting cockeyed in my S1, held in by two little bungee cords!  Hey Dean! wanna come over and fix it for me?  HBJ "Most motorcycle problems are caused by the nut that connects the handlebars to the saddle." --Anonymous HellBuelly Sage | ||
| Buellerthanyou |
Oh yeah! You can unscrew the gas cap ring and take the whole shebang out. Then you should be able to unscrew the bottom of the cap from the "inside" to get it out. Unfortunately, if it's wallowed out, you either have to buy a whole new (or used) cap or try to fix it using one of the methods described above. They don't sell individual pieces of the cap mechanism separately. HellBuelly J Hillcountry HellBuellies | ||
| Buellerthanyou |
Oops, one more thing. You can tell if the battery tray conversion has already been done by looking at your voltage regulator. If it is laying down beside your battery, NO. If it is standing up beside your battery, then YES. If yes, then the 65948-00 or any compatible (pretty much every battery manufacturer will have something similar) will work. That is all... HBJ "Cogito ergo Buell; I think, therefore I ride a Buell." --Rene' "I Ain't A Girl" Descartes | ||
| Milesvdustin |
OK, well I do have the battery conversion done. I bought an Eveready performance battery from wal mart today, it is on the charger getting juiced up for my weekend ride. I am going to ride all up the outer banks of north carolina, take the ferries and stuff. Well, as long as I can fix that dang gas cap. New one is 55 bucks from the dealer. Tomorrow morning I will be trying to get the cap out. Thank you all for the help! | ||
| Olbolt |
This really sounds dumb, but my S3 has a locking cap, recently the lock center vibrated radially from the unlocked position on its own, prohibiting the lifting tang of the cap from rotating. I just moved the center lock ring around so the key slot was towards the rear of the tank, then the lifting tang would rotate and the cap would open. | ||
| Milesvdustin |
Ratbuell was right, I had to pry the hell out of that thing to get it off. When I pried it off, some slivers of the plastic shaved off into my tank. I took a knife and a flashlight and fished them out by stabbing them. I am going to file the dang thing down at work tonight and see what happens. I will post some pics of the finished product. | ||
| Oldog |
I have not seen many messages about this till all of a sudden I wonder if there cutting the gas with something? and the plastics dont like it? | ||
| Kmbuell |
I don't think it the gas, but rather the lack of it. If the rubber dries out it shrinks and contracts onto the cap mechanism. Once it comes apart, soak the ring in fuel or fill the tank and don't fully tighten the cap (best done at home from a gas can) for a day until the rubber swells again. Kind of the opposite issue of the carb diaphram, which i have to dry our for a day before i can ever get it back in it's groove. My M2 lock spins on occasion, usually takes me a minute to think about pulling the key out to "unlock" mu unlocked gas cap. Good Luck, and thanks for your service. | ||
| Milesvdustin |
Here are the pics of the finished product!   | ||
| Buellistic |
Just got done doing this myself ... | ||
| Ratbuell |
Looks just like my cap! Glad to help out, and welcome home! |
