Gas caps stuck: 1999 Pro Sport

S

Soul Man

Member
I hardly ever ride my bike anymore, but try to start it and ride a bit every now and then to keep it working.

tried to take off gas caps to check fuel level and add some Seafoam and they are both STUCK. With a big adjustable wrench and/or oil filter strap wrench I can get them to move, but it seems like the chrome cap is spinning on the actual cap. even with masking tape and rags a got a small scratch on my paint around each cap :-(

How the hell do I get these off????? I figure I need new ones, so don't mind destroying them if need be, but don't want any more damage to my paint and tank >:-(
 
Mr. Wright

Mr. Wright

Knows some things
First off, you will get more help, if you start here. http://www.bigdogbiker.com/forums/introductions.2/
Next, I hope you do know that the left one is left handed threads.
Next, the reason they may be stuck is, if you ever used gas with ethanol in it, it will swell the threads.
Lucky for you there is a guy close to you that makes new threads for your caps, and or new custom caps, with aluminum threads.
http://www.bigdogbiker.com/members/bbchopper.252/
Lastly, do not put additives in your tank, it will make the liner peel.
 
francoblay1

francoblay1

The Spaniard
Soul Man said:
I hardly ever ride my bike anymore, but try to start it and ride a bit every now and then to keep it working.

tried to take off gas caps to check fuel level and add some Seafoam and they are both STUCK. With a big adjustable wrench and/or oil filter strap wrench I can get them to move, but it seems like the chrome cap is spinning on the actual cap. even with masking tape and rags a got a small scratch on my paint around each cap :-(

How the hell do I get these off????? I figure I need new ones, so don't mind destroying them if need be, but don't want any more damage to my paint and tank >:-(
Click to expand...
You need to check THIS out! :oldthumbsup:
 
S

Soul Man

Member
Mr. Wright said:
First off, you will get more help, if you start here. http://www.bigdogbiker.com/forums/introductions.2/
Next, I hope you do know that the left one is left handed threads.
Next, the reason they may be stuck is, if you ever used gas with ethanol in it, it will swell the threads.
Lucky for you there is a guy close to you that makes new threads for your caps, and or new custom caps, with aluminum threads.
http://www.bigdogbiker.com/members/bbchopper.252/
Lastly, do not put additives in your tank, it will make the liner peel.
Click to expand...
Thanks for your reply. I do know about the reverse threads on the L. Both of them are really stuck.
Any clue on removing the old ones????

I assume they are aluminum caps, so I should be able to use a grinder to cut away the aluminum, or cut a hole in so I can get something to grab the threaded section (which is plastic as I recall(?)). I don't want to start grinding/drill and hit anything steel (with the ensuing sparks).
The aluminum seems to be spinning (barely) without the part threaded into the tank moving.
 
Mr. Wright

Mr. Wright

Knows some things
DO NOT GRIND! We just met you, don't want to blow yourself up. I've used a rubber strap oil filer wrench before, or any kind of oil filer wrench will do. Spray some lube up in there and see if that helps.
As a last resort, you can drill down through the center of the cap, then chisel the plastic piece out.
Someone correct me if I'm wrong, that's the same style of cap on the 99's, that on the 01 and up to when ever they changed the style again?
 
FrankBDPS

FrankBDPS

Well-Known Member
Mine does not have stock caps on it. If it is the soft tail design with two tanks it should be the same.
 
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