I give up, how the F&CK do you get the gasket back on the filler cap?

[SaltLick]

Ive spent the last 2 hrs straight trying to get that little stupid ass O ring gasket back on the filler cap/on the tank, i give up......


How the hell do you do it? how does it go on? Do you put the gasket on the tank first, then try to put the cap thing on or do you leave it on the cap thing? either way ive tried it a million different ways and it wont go on. Please god someone help me im about to loose my mind. 

Oh and it doesnt help that the dam gasket can be turned a bunch of different ways that seems like it would work.

[DuciD03]

what bike is it?

I did it once after replacing my fuel filter on mt 800 ie 03 ... patience dude; ... this is what I recall but its been a while ...

use double layer of masking tape to protect the tank so you done scratch her in the process; 2 lockable sergons needle nose pliers and some grease; well grease the gasket so it can easily slide into place; clamp the gasket in 2 spots to the cap surround and then press into place the make sure you hold it firmly in place while you put the very fiddly allen screws back without dropping them down the gastank hole or (pot a rag in it! and the drain hole, a small screw).  I did it on my own but a second set of hand would be helpfull; I recall sweatting as I was trying to put the allen screws in; also the gaskets tend to swell when they get older so therer more difficult to install ... be patient have fun!  ha ha I feel your pain dude  [moto]

post back when your done

[Ddan]

Are you talking about the green o-ring on the bung, or the black one that seals the filler assembly to the tank.  If it's the black one, you do need some patience.  If you get it in place on the filler assembly, it will *sorta* stay there.  Lube the green o-ring so it's easier to stuff the bung into the tank and have all the little grub screws already started so you don't have to dick with them while you're trying to hold everything in place.  It's really not hard to do, just a bit fussy.

[Slide Panda]

I just did this a couple weeks ago so I feel your pain.

I got the black ring seated around the bung and flattened out.  Once I got it there I kept both hands wrapped around the damn thing to keep it flat.  Thumbs on top with fingers splayed out as much as I could and wrapped my fingers around so the tips were under the lip of the bung/gasket.  Think of making your hands like an alien Face-hugger.

Then press the bung in as far as you can w/ your fingers in place.  Then work your fingers away from one side of the bung/gasket while working to press that same edge down against the tank.  If you can get that going just keep working around.

It's a PITA for sure, but that method worked pretty well for me.

I've heard some people get plastic forceps or clips to hold that black gasket in place while they maneuver the bung.  not sure where to get them though

[sbrguy]

i've watched my mechanic do this twice and each time it took him literally no more than 30 seconds tops to put the rubber oring on with just his hands and it "looked" really easy.

no reason to lose your mind over that. right?   

ask speeddog or stu how to do it those are the guys to ask.

[ducpainter]

I've done it once or twice...

it's really not that hard.

[mookieo2]

I feel your pain too. Just take your time. Make sure all the set screws are not going to interfere with the installation. I also used a rubber mallet to seat the cap into the tank after I got the gasket on.

[supertjeduc]

It's easy if you know how to do it
Just put your filler cap almost in place
You need it to be about 2mm above what it should be
Than you do that gasket around the fillercap
And than you hit the cap in place

[2001cromo]

Nate, you're too modest!

I agree with what the poster directly above me is saying about "putting the cap itself almost completely in and then work the lubed black gasket on"

But the important part to me is just pushing the whole assembly down and it pops into place. I would not recommend using either a mallet or hitting it.  Maybe just tapping it lightly. (knowing me I'd end up pushing the whole top of the tank in...)

Then start on the grub screws.

HTH and GL

[ducpainter]

Nate, you're too modest!

I agree with what the poster directly above me is saying about "putting the cap itself almost completely in and then work the lubed black gasket on"

But the important part to me is just pushing the whole assembly down and it pops into place. I would not recommend using either a mallet or hitting it.  Maybe just tapping it lightly. (knowing me I'd end up pushing the whole top of the tank in...)

Then start on the grub screws.

HTH and GL

I don't do it that way.

I lube the o ring and try to keep the gasket dry.

I put the gasket in place and install the thing.

Works for me.

[ducrider45]

I've done it once or twice...

it's really not that hard.

+1 Put the cap assembly in first. Do not tighten all the way. Then just work the gasket around it. Tighten everything up.

[erkishhorde]

If you can't get it back in just do what Nick said in your other post.

It'll just come out again if you reinstall it.
Put it in your 'take-offs' box.

Just don't over-fill the tank now, leave some air space.

Best tech tip evah! 

Thumbs on top with fingers splayed out as much as I could and wrapped my fingers around so the tips were under the lip of the bung/gasket.  Think of making your hands like an alien Face-hugger.

[ScottRNelson]

It's easy if you know how to do it
Just put your filler cap almost in place
You need it to be about 2mm above what it should be
Than you do that gasket around the fillercap
And than you hit the cap in place

This is what I was going to suggest, and explained quite clearly.

It's a reminder that I need to get a new rubber piece for my 888, since the old one is all cracked.

[SaltLick]

It's easy if you know how to do it
Just put your filler cap almost in place
You need it to be about 2mm above what it should be
Than you do that gasket around the fillercap
And than you hit the cap in place

so take the black gasket completely off, put the cap thing down on the tank but dont completely seat it, then stretch the black gasket over the top, then hit the cap in place and it will push the gasket in with it.....i think i get it.

[SaltLick]

oh heck i took it down to motocorsa at lunch time since im a few blocks away from there. They got it on for me.  Nice bunch of guys there.  Sometimes, it just aint worth it.