1980 XS 1100 special-- rubber seal on Gas tank filler cap?

[jerro]

Hi all, wonder if anyone has a `quick fix` on the `rubber seal` that stops the gas coming out of the filler cap other than buying a whole new unit or something? Looks to me that you could pull off the old one and `glue` on an o ring or flat rubber washer? Didn`t want to pull mine off until i had a few ideas!--Thanks in advance--Jerro

[XS1100 Newbie]

In the tech tips, there is a tip on changing the gaske using a radiator seal. I did it, and works just fine.

[crazy steve]

Link to above repair.... http://www.xs11.com/forum/showthread.php?t=35444

[jetmechmarty]

Here's one that will last another 30 years. I put this one on my bike.

2M0-24641-00-00 GASKET,CAP 1

Mike's XS has one that probably won't last that long, but is cheaper.

Gas cap Rubber Seal 1976-84

Whatever route you take, when you disassemble this, there is a piece of foam in there that is a filter for the vent. It may be rotten. If so, the vent won't work and your bike will periodically stall from lack of fuel. I replaced mine with a small piece of Scotch-Brite.

[jerro]

1980 XS 1100 special-- rubber seal on Gas tank filler cap?

Thanks everyone, appreciate that. I am now inspired and will get on and fix it--Cheers to you all------------

[fredintoon]

Hi all, wonder if anyone has a `quick fix` on the `rubber seal` that stops the gas coming out of the filler cap other than buying a whole new unit or something? Looks to me that you could pull off the old one and `glue` on an o ring or flat rubber washer? Didn`t want to pull mine off until i had a few ideas!--Thanks in advance--Jerro

Hi Jerro,
you can still buy the correct seal, it's the same one on every XS series bike.
The trick is in knowing how to change it.
The 3 screws you see when the cap is open aren't all that holds the rubber on.
You have to take the lock off which lets you pull the metal springything out of the cap.
Once the spring plate is in your hand you can see the E-ring that holds the seal rubber on.
Slide the E-ring off to get at the core to replace the dead rubber with a new one.

[Eveready1100]

I posted a handy tip on getting the clip undone easily on the Aussie site. here it is, if it helps -

I finally got around to replacing the rubber seal on the fuel cap. After removing the cap from the tank, I flipped it over and undid the two small screws holding the lock mechanism in place. If doing this for the first time take care to support the lock barrel, and note where the sliding plate fits into the latch, as it can take a few goes to reassemble it correctly.
After removing the latch assembly, swing the inner plate up on the hinge to reveal the E clip holding the cap seal in place.
Now here's the tip..........................


^ A couple of bits of 3x2 in the vice plus another spacer and clamp the cap in position using a valve spring compressor


^ Makes for easy access to get the E clip undone without having to wrestle with the spring underneath.


^ Once the clip is removed, release the compressor and it all just comes apart. Then undo the 3 screws in the centre of the cap sealer and flip the remains of the old seal off the lip


^ while it's in this state, I gave everything a good clean, in particular, the little round plate that sits inside the cap, as the hole in the centre of it is usually the cause of venting issues if it blocks up.


^ The reassembled cap centre with its new seal


^ Here's the top side of it where the spring sits.

Now it's just a matter of putting it back in the valve compressor to take the pressure of the spring and snapping the E clip back in place, then reassembling the rest of the cap. Easy as.

[DGXSER]

If I recall correctly, there is no need to disassemble the three screws and the vent filter section to replace the stock gas cap seal. Not that it would be a bad idea to do it and get the vent clean. Just not required to accomplish the task at hand.