Question regarding tank door modification

[HANDSOME JIM]

I recently removed my gas tank cap in preparation to turn it around 180 degrees. I didn't realize that it would be necessary to modify the center tank cover as well. I decided not to do this but when I tried to reinstall the lid in it's original position I ran into a problem. I cannot get the 3 rubber spacers back in thier original position. It looks like this would be much easier if I could remove the center cover panel from the bike first. Can anyone tell me how to do this or is there a trick I am missing reinstalling the rubber spacers?

[Pastor Passum]

Jim, I can tell you 2 things. First is that you're not the only person to have trouble getting the 3 rubber wedges back in place. The second is that I swore I'd never take the cover off again as I had the same problem as you. It's been almost 2 years but I do remember finally taking the center tank cover piece off, placing everything in place upside down and carefully turning the assembly over and onto the tank. I always figured there was a simple way to do this but I never figured it out. If you do post here and perhaps I'll rethink my second statement and reverse my lid also. Good luck

Jim

[HANDSOME JIM]

Thanks for the input Reverend. I wound up doing exactly as you did and like you I will NEVER remove the filler assembly again.

[xjon]

I don't remember how I did mine either. Mental block! I do remember that i dropped one of those rubber wedges inside the tank. I had to drain the tank and remove it to be able to dump it out.

[damoace]

I've managed this a few times now. Practice making perfect and such. The key points are:

Stuff Rag down filler neck (learnt the hard way. Rubber bung still in the tank to this day on one of my 1200's)

Use dab of grease to hold rubber bungs on lip of tank cover.

Tiny smear of grease (or WD40) on curved face of rubber bungs to help filler cap assembly slide into place without gripping and moving the bungs out of place.

With filler cap surround in place, open filler cap and use small flat-blade screwdriver to carefully push bung back under the rim if it managed to move when you put the surround in place.

Whizz 'round the bolts in a diagonal sequence the same way you would do up wheel bolts to even out the pressure on the sealing faces.

Finally, with just the filler cap screws in and no other bolts holding the tank cover in place, gently "jiggle"" (or joggle, wobble, gyrate, snaggle or just plain move a bit) the tank cover about. Gently. You wont break anything, the filler cap is bolted to the tank, not the tank cover. This helps to "seat" the rubber bungs in properly. Go EASY though. It'll move freely but not too far.....

Dont forget to take the rag out either.....

Job Done, Head for Pub....




P.S. Before any and all of that, take the time and pull the filler neck out of the tank and drill two 8mm holes (one 5mm above the other) in it. It'll speed up the filling time no end, you still end up with an air gap if you drill them at the right hieght (say along about 1o-15mm down from the top for the first hole) so expansion worries are not an issue. It wont give you more fuel in the tank as such, but it works out that way because its faster to fill fully so you are less inclined to get bored before you are full and give up......

[kindofblue]

Originally Posted by HANDSOME JIM

I recently removed my gas tank cap in preparation to turn it around 180 degrees. I didn't realize that it would be necessary to modify the center tank cover as well. I decided not to do this but when I tried to reinstall the lid in it's original position I ran into a problem. I cannot get the 3 rubber spacers back in thier original position. It looks like this would be much easier if I could remove the center cover panel from the bike first. Can anyone tell me how to do this or is there a trick I am missing reinstalling the rubber spacers?

Forgive this potentially stupid question from a newbie GS owner. Are you referring to pulling off the metal ring assembly for the gas cap or the plastic cover over the actual tank itself?

The reason I ask is that I was thinking I might have to pull the plastic cover off to run wiring for my radar detector and GPS. Thanks!

[PotatoHead]

Don't pull the plastic off of the tank to run wires, just take off the tank and run the wires along the frame, then reinstall the tank. A bit of a nuisance but not a big job.