Fuel Cap

[dennis49]

I'm new to this board and I have a question on a problem. I hope I can find an answer. I have to replace the fuel cap on my 2001 Nomad FI and I need information on how to remove the key tumbler from the old cap to install on the new cap. Any help on this would be greatly appreciated, gas in the lap is not a fun thing at 70 mph.
Dennis

[redjay]

Hi. Cant help you with your questions but is it a seal that is leaking ? Why not replace the seal. Is it not sold seperately ? If you cant figure out how to take out the tumbler take the cap to a locksmith ?

[cactusjack]

I tried checking the parts fiche at cheapcycleparts.com to see if there is an exploded view, but since the fuel cap is sold as a complete assembly, there wasn't one. I checked my service manual and it has very little information regarding the fuel cap.

Unless someone else here has replaced their lock tumbler, you may be on your own. I have had my fuel cap apart, but can't recall if I even tore it down far enough to see the tumbler.

[ringadingh]

Im sure a locksmith could get it out for you, but doesn't the new cap come with a lock cylinder? I think your original key will still open the new gascap.

[dennis49]

I have not received the new cap yet it should be here next week. I tore my cap down all the way and could not find a way to get the tumbler out, I did find the bad O ring that is allowing the fuel into the key hole but it is a special design and can not be purchased. I have been told the cap does not come with the key tumbler.

[Top Cat]

I realize it is to late now but did you try taking the key out of the ignition and riding with it in the gas cap to see if that stopped the gas from coming out and getting into your lap?

[eagle]

Does the gas leak only when the gas tank is full? Are you overfilling the gas tank? You are supposed to only fill the tank about a 1/4 inch above the fill tube. There is another seal to add/install if the gas is leaking when the tank has been filled and it only costs about $4.00.

[dennis49]

I do not over fill, I fill with the bike standing straight and the gas level to the bottom of the inside basket. When on the side stand the gas is about 1" below this inner basket. It is coming from the key hole not the base of the cap and it comes out even after I turn off the ignition. The O ring for to keep this from happening is obviously worn and it's not available anywhere I have found. It is a small O ring much smaller than a dime it has a slit running the circumference so when the tank is under pressure the O ring will expand and tighten up against the wall the tumbler rides in.

[AlabamaNomadRider]

I would check with a locksmith as someone suggested. I have looked at the lock and haven't figured out how to get it out. It is probably pressed in and has some type of catch that holds it in. A good locksmith should know how to get it out.

[dennis49]

I will give that a try. It must not be hard because they sell the cap without the lock so it must be something easy I'm overlooking. There might be a small hole to put a paper clip or something like that in to push a release like on some car ignitions.

[dennis49]

The tumbler change out was not all that bad. I disassembled the old cap and there is one tumbler at the very bottom that holds it in place. I took a small screwdriver and moved it inward and pushed the tumbler out.

Putting the tumbler in the new cap was as easy as pushing the tumbler in the hole until it bottomed out and it was done.

Both steps had to be done with the key in place to hold the tumblers.
Now there is no more gas leaking out the key hole this fixed my problem.

There is probably an easy way to move this tumbler inward like a lock smith pick or something if there is a next time this will be an option.

Dennis

[ringadingh]

Hopefully there won't be a next time, we don't here of too many gas cap problems. Im sure yours was just an isolated incident.

[lw]

Thanks for the follow-up report. Lucille has developed the gas through the keyhole issue in the last few weeks.

[redjay]

Is this a pressure build up problem ? Have you had the tank off recently and kinked a vent hose? Or is it plugged ? Maybe neither but worth checking.

[dennis49]

It would not matter if vent was plugged or kinked. In those circumstances the fuel would leak from the rubber gasket and spill on the tank from under the cap. It should not come from the key hole. In the case of the key hole the only fix is a new cap the O ring for the lock mechanism is a special split O ring and a normal rubber O ring will not work.