Gas cap stuck

[otter1]

My recently purchased 900ie was sitting for awhile and I think the gas cap inner flange is rusted/stuck.

The key only turns about 45 degrees so I cannot open the lid.

I took it to a locksmith and he said to pour oil inside the tank and let it soak for a few days them tap in the lid while trying to turn the key. I have done that and it still wont open. 

Any tips on how to get the cap open?

[ducpainter]

The key doesn't need to turn very far to operate the lock.

I' use a small screwdriver or pointed wooden stick to pry while the key is turned.

[otter1]

Thanks for the reply,

I opened and tested the cap on my 848 -- the key turns clockwise 90 degrees  to pull in lower latch so it can open.

The monsters gas cap looks the same so figured it was not pulling the latch mech in enough.

I tried to use a screw driver to pry the lid up while turning the key -- but did not force it, since I was afraid it would break.

I may end up having to destroy the cap, I guess the only way to open it is by drilling out the center through the lock?

[ducpainter]

Thanks for the reply,

I opened and tested the cap on my 848 -- the key turns clockwise 90 degrees  to pull in lower latch so it can open.

The monsters gas cap looks the same so figured it was not pulling the latch mech in enough.

I tried to use a screw driver to pry the lid up while turning the key -- but did not force it, since I was afraid it would break.

I may end up having to destroy the cap, I guess the only way to open it is by drilling out the center through the lock?

Did you try any lube in the lock?

The only way without activating the lock with a key would be to destroy things.

[WTSDS]

Before drilling thru the lock barrel I would put many drops of oil/spray lube down past the cap at the front where the latch is and rap on the cap and surrounds with a nylon hammer, giving the key a gentle turn now and then. Aim is to shake the rusted mechanism loose - rap, rap, rap, don't bash, tempting tho it will be.

[otter1]

Well - Tried the above ^ but no avail so I had to finally bite the bullet and cut it off. Drilled a hole to remove under cap ring bolt and the lid came right out without unlocking.





You can see in the pics the rust holding the latch.

Now I need to pull the opening section to service the fuel pump and filter then I have a friend with a small sand blaster that I thought I could use to gently clean the inside tank rust - 8 allen screws and the rubber seal removed but it wont come out 

I read it is supposed to just pull straight out- Right?

[ducpainter]

With the cap as rusted as it is that piece probably has a fair amount of corrosion too.

Stick a hammer handle in the opening and use it like a lever. It will probably take a pretty firm rap.

Keep your other hand under the head of the hammer to avoid the inevitable contact.

[WTSDS]

Did you undo the 3 little screws going horizontally ?

[otter1]

Thx for the replies -- really appreciated!

I FINALLY GOT IT OUT!! Used the hammer handle and pried at 12,3,6,9 o'clock multiple times and with alot of force and out it came  

This model had eight small allen head screws in the inner rim holding (horizontally) the piece in place. Yes, I had removed them all prior to my latest post.

Got the pump and filter out. Will test the pump and replace the filter.

Now re: the rust?  Should I coat the inner tank with some product/spray after a gentle scrubbing??

[ducpainter]

Thx for the replies -- really appreciated!

I FINALLY GOT IT OUT!! Used the hammer handle and pried at 12,3,6,9 o'clock multiple times and with alot of force as out it came 

This model had eight small allen head screws in the inner rim holding (horizontally) the piece in place. Yes I had removed them all prior to my latest post.

Got the pump and filter out. Will test the pump and replace the filter.

Now re: the rust?  Should I coat the inner tank with some product/spray after a gentle scrubbing??

You should definitely coat it. It may actually be perforated.

There are different coatings that require a different level of clean.

I believe that the rust should be removed.

It will take a while to get that rust out.

[otter1]

I have ordered a new fuel filter from Ducati ($31.00) was going o use a purolator one I got for ($5.00) at pep boys but read on a suzuki forum the were prone to bursting so, decided to pay $$ for the Ducati one.

I also ordered a gallon of rust remover - saw this video on you tube www.youtube.com/watch?v=Hb7jyf7A4WE

-- LOL hope it works as advertised.

In the meantime I am using a few dowels and a small iron bar to gently tap out the dents.

Will then locate a used gas cap from someplace online and get the locksmith to change the lock to my key and Im done!

[otter1]

Metal rescue worked alittle but I was not really impressed. I poured the whole gallon in and then rotated the tank every 6 hours for 24 hours or so to hit all sides.

The tank has very narrow surfaces along both sides and the vent and fuel line tubes prevent placing a CHAIN inside and shaking it around to scour the rust. This technique has been recommended on other websites to help remove rust from inside fuel tanks.

I want to coat it with something before reassembly or it will just get worse. Unfortunately all the products I reviewed recommend the tank be "free of rust" prior to coating and it is not -- LOL.

[Thermite]

I think I would keep an eye on eBay and the parts for sale section.  You can also check with the salvage shops.  Gotham Cycles and Ducati Depot come to mind.

 That tank looks toast to me and if you can find one with a viable cap you'll come out ahead.

[Cloner]

Try Caswell's tank liner.  They simply ask you to throw a few drywall screws in the tank with some acetone to remove "loose rust", then clean it and apply their coating.  They claim it sticks better to a rusty surface as long as nothing is flaking.  I've used it on worse tanks than yours to excellent results.  You'll want to plug the ends of the internal steel hoses before coating to avoid blinding them, along with your other prep.

I've got a spare gas cap I can part with cheap if you need one, as long as you don't mind a Cagiva elephant cast into it.  You'll want to disassemble the one you have and pull the tumblers out for use in the replacement so that you can keep your single key arrangement.

[ducpainter]

Try Caswell's tank liner.  They simply ask you to throw a few drywall screws in the tank with some acetone to remove "loose rust", then clean it and apply their coating.  They claim it sticks better to a rusty surface as long as nothing is flaking.  I've used it on worse tanks than yours to excellent results.  You'll want to plug the ends of the internal steel hoses before coating to avoid blinding them, along with your other prep.

I've got a spare gas cap I can part with cheap if you need one, as long as you don't mind a Cagiva elephant cast into it.  You'll want to disassemble the one you have and pull the tumblers out for use in the replacement so that you can keep your single key arrangement.

As a painter...I just can't buy the Caswell process.

I'm a POR guy. It takes longer, but you actually remove the rust rather than hiding it.