Gas Tank Key Flap

[Alan]

How do you remove the flap that covers the gas tank key? I use a tank bag and it is a pain to use the key, so I want to remove the flap and will use a key with a knob on top to open the cap.

 

[Swagger]

Could you not just replace the fuel filler assembly with a keyless system? Saves having an odd looking gas cap.

 

[markjenn]

It looks like you can do some disassembly of the cap if you remove the screws from the bottom. I don't know if that gives you access to the hinge pivot on the flap. You an remove the entire cap assembly from the tank to facilitate access.

Are you planning on leaving the "knob" in the tank all the time? I don't understand how this is better from the perspective of fitting a tank bag.

- Mark

 

[Alan]

Are you planning on leaving the "knob" in the tank all the time? I don't understand how this is better from the perspective of fitting a tank bag.

- Mark

Yes, the knob is actually a key cut with a knob on top. The knob sets flush with the tank. So you just turn the knob instead of having to remove the key from the ignition. I'll take a look at accessing from the bottom of the cap.

 

[stevepsd]

The flap is held on with a simple straight pin. You have to disassemble the cap to remove it. Simply remove the cap assembly from the tank (allen head screws), remove the couple of screws securing the cover to the bottom of the cap. Make sure the cap is laying flat and you have a clean work area as there is a small ball bearing & other bits in there, so work slow and carefully.

 

[Alan]

The flap is held on with a simple straight pin. You have to disassemble the cap to remove it. Simply remove the cap assembly from the tank (allen head screws), remove the couple of screws securing the cover to the bottom of the cap. Make sure the cap is laying flat and you have a clean work area as there is a small ball bearing & other bits in there, so work slow and carefully.

Thanks Steve. This option allows you to have keyless fillups without laying the lid down somewhere and leaving it at the gas station. I'll work on this on the weekend.

 

[Tremor38]

Thanks Steve. This option allows you to have keyless fillups without laying the lid down somewhere and leaving it at the gas station. I'll work on this on the weekend.

??? I hear ya buddy! it's really a load reaching up there, pulling the key from the ignition (almost broke my back doing that once) and moving it aft a whole 2' to the gas tank, then, whew!, I have to move it all the way fwd again! To top it off, I have to suffer through this roughly every 200 miles....I don't know how we all soldier through it sometimes :-\ I almost quit riding because of the strain. It's a wonder I've put up this nonsense all these years. It's such an energy drain that I often have to cut my ride time in half, if there's more than one fuel stop....heck, sometimes I go straight for a hotel, shower and beer after one exhausting session of hefting that key back-n-forth. I'm glad I read this post. Stay safe out there!!

 

[Alan]

??? I hear ya buddy! it's really a load reaching up there, pulling the key from the ignition (almost broke my back doing that once) and moving it aft a whole 2' to the gas tank, then, whew!, I have to move it all the way fwd again! To top it off, I have to suffer through this roughly every 200 miles....I don't know how we all soldier through it sometimes :-\ I almost quit riding because of the strain. It's a wonder I've put up this nonsense all these years. It's such an energy drain that I oftern have to cut my ride time in half, if there's more than one fuel stop....heck, sometimes I go straight for a hotel, shower and beer after one exhausting session of hefting that key back-n-forth. I'm glad I read this post. Stay safe out there!!

Temor, I'm an Iron Butt Rider. It is much easier and faster to unlatch the tank bag and turn a knob. If you have ridden 1500 miles in 24 hours, you will understand the importance of those few seconds.

 

[jajpko]

Temor, I'm an Iron Butt Rider. It is much easier and faster to unlatch the tank bag and turn a knob. If you have ridden 1500 miles in 24 hours, you will understand the importance of those few seconds.

I understand what you are saying. I don't get off the bike when I fuel, just pull off the tank bag and put it in front of the bars.
Invariably, I will leave the keys in the ignition and have to move the tank bag to pull the keys.
At the vary least, it is aggravating and a waste of time.
Your idea sounds interesting.

 

[Tremor38]

Temor, I'm an Iron Butt Rider. It is much easier and faster to unlatch the tank bag and turn a knob. If you have ridden 1500 miles in 24 hours, you will understand the importance of those few seconds.

OK, I see rationale the now. You Iron Butt riders are a special breed though. Once is enough for me... and that's just the 1000 miler

 

[Swagger]

.... ??? I hear ya buddy! it's really a load reaching up there, pulling the key from the ignition (almost broke my back doing that once) and moving it aft a whole 2' to the gas tank, then, whew!, I have to move it all the way fwd again! To top it off, I have to suffer through this roughly every 200 miles....I don't know how we all soldier through it sometimes :-\ I almost quit riding because of the strain. It's a wonder I've put up this nonsense all these years. It's such an energy drain that I oftern have to cut my ride time in half, if there's more than one fuel stop....heck, sometimes I go straight for a hotel, shower and beer after one exhausting session of hefting that key back-n-forth. I'm glad I read this post. Stay safe out there!! ....

) ) you piss taking SOB

 

[GrahamD]

??? I hear ya buddy! it's really a load reaching up there, pulling the key from the ignition (almost broke my back doing that once) and moving it aft a whole 2' to the gas tank, then, whew!, I have to move it all the way fwd again! To top it off, I have to suffer through this roughly every 200 miles....I don't know how we all soldier through it sometimes :-\ I almost quit riding because of the strain. It's a wonder I've put up this nonsense all these years. It's such an energy drain that I oftern have to cut my ride time in half, if there's more than one fuel stop....heck, sometimes I go straight for a hotel, shower and beer after one exhausting session of hefting that key back-n-forth. I'm glad I read this post. Stay safe out there!!

This is why Ducati has an electronic system. It saves all this fatigue, when it's working. You can't have those Ducati owners straining themselves.

But, on the other hand if you have to do a quick fill and go in a competition, well then it's a competition mod then isn't it.

 

[N2 Overspeed]

Alright since we're on the gas cap topic - any locksmiths out there that know how to modify the cap to unlock and then be able to remove the key? (with the cap still open) my old BMW was that way and it was much easier (also saved the tank from key scratches) ideas?? ::001::
TIA

 

[Tremor38]

Alright since we're on the gas cap topic - any locksmiths out there that know how to modify the cap to unlock and then be able to remove the key? (with the cap still open) my old BMW was that way and it was much easier (also saved the tank from key scratches) ideas?? ::001::
TIA

That seems like the ideal way to go about it. Might be a simple mod if you can get the tumbler out.

 

[Alan]

That seems like the ideal way to go about it. Might be a simple mod if you can get the tumbler out.

I removed the flap yesterday. As posted earlier their are a bunch of little parts there so you need to tear it apart on a clean workbench. One of the small pieces is a black T shaped piece. I'm not sure but I think the only purpose for this piece and the spring behind it is to keep you from removing the key when the cap is open.

I'll post a picture of my mod when the compound drives in the key/knob.

 

[Alan]

Here are the pictures of my gas cap mod. You have to disassemble the cap as noted below in order to get the flap off. As warned be careful, there is a ball bearing, several springs, and a little plastic piece.

 

[Andrew S]

Alan-
You mentioned a black plastic piece earlier. Are you able to remove the key when the cap is open now that the black piece is removed?

 

[Alan]

Alan-
You mentioned a black plastic piece earlier. Are you able to remove the key when the cap is open now that the black piece is removed?

I didn't remove the black plastic piece. I already had the cap reassembled when the question about removing the key when the lid up was ask. I THINK that is the purpose of the little black piece but am not sure. With my knob concept, I don't ever need to remove the key.

 

[EricV]

Alan-
You mentioned a black plastic piece earlier. Are you able to remove the key when the cap is open now that the black piece is removed?

I'm not Alan, but this will lead you down the rabbit hole - http://www.fjrforum.com/forum//index.php?showtopic=18042&st=20&p=722219&#entry722219

Good pictures and shows the parts that you need to remove for a gas cap that allows the key removal with it open. It's the FJR Forum, so you may have to subscribe or log in to see everything. Worth it.

I pulled my FJR's cap apart on a towel over my top case in a parking lot before an endurance rally because I had some venting issues with my fuel cell at the time. It was the simplest way for me to correct the problem at the time. I left in the T shaped piece that is the key interlock that prevents key removal. Some LD guys don't really have issues with the key in the cap part, others do and Alan's solution is not uncommon on various brands of bikes. That issue, IMHO, is more about having a routine than any time savings, real or perceived, during a gas stop.

Anyway, it's not a hard mod to make if you have some basic tools, a little common sense and the advantage of having seen what does what before. Go for it.

 

[Alan]

I left in the T shaped piece that is the key interlock that prevents key removal. Alan's solution is not uncommon on various brands of bikes. That issue, IMHO, is more about having a routine than any time savings, real or perceived, during a gas stop.

The T shaped piece was black on my bike and I thought it might be the key interlock. I left it in. I agree about routine versus time savings. On my KLR I have a knob on the ignition and leave it in the bike all of the time.