Tank cap doesn’t shut

I sprayed a spare tank on another 89 fk that came without a cap, took the one off the other tank, fitted it and now it won’t lock, put it on the bike to make sure and it won’t operate the release for the locking tangs to hold the damn thing shut

Any ideas?

 

That is weird. Does it line up without putting in the mounting bolts? it doesn't take much to make those not work.

 

It fits like Honda made it, just won’t fucking click

 

I know I had manually manipulate the spring loaded parts to function when I was transferring caps before. I basically had to stick the key in and put pressure on the locking tabs. Eventually it became unstuck and sprung out while off the bike. Once it did that, I twisted the key as if I was going to unlock the tank and once the tabs retracted I mounted the entire assembly. Pressed down after bolting on and it worked like normal. Results may vary, but I do remember having my cap not spring out for a bit in the beginning.

 

Thanks for the advice, I’ve narrowed it down to the cap fitting at a different angle, the lid only touches at the front and not the 2 sides it needs to spring out

I could probably file the rear posts down to change the angle and then I have a cap that only fits one tank …..very annoying

 

You could always shim the cap back up and level for another tank.

That's a weird one tho.

How much of the fuel cap well got painted? Did paint pool down there and is thicker than stock?

 

The tank well had hardly any additional paint on, I’ve been messing around with it and I’m going keep the cap for the tank it came off as it’s less compromised by rust than the one I’ve been painting

It never occurred to me to try the filler cap on the tank before I painted it

I suppose the only option that would work is one of the Chinese ones and drill the holes as required with a locknut underneath

 

I wouldn't have either. I've never ran across that switching between the same model. I will now though.

 

The older Kawasaki ZX-6/9/10 shares the same bolt pattern as the early VFR. It is not the same as every other Honda from the 90s-00s.


It's not a direct bolt on, I had to machine the OD down to fit the well and make a new custom gasket out of sheet Viton rubber. Also shimmed it just a touch to get the reveal correct and have it bottom out and tighten correctly. My buddy didn't shim his and it is fine though.



But when done it is perfect, been using it for quite a while. I've made three now.

 

That’s a neat piece of work, unfortunately I disposed of my lathe in’21

 

I have a Tyga fuel cap now. I did have to open up the through holes with a slightly larger drill bit and made a thinner gasket between the tank and filler cap. But this was the result.

 

(IMG)

I don't even see your pic if I hit "reply".

 

I can't see it either...