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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Seized fuel cap
Post Info TOPIC: Seized fuel cap
shad


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Seized fuel cap
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Hey guys my fuel tank cap is seized I'm not sure if its rusted to the tank or if the locking mechanism on the cap is seized i can turn the cap with some effort but if i put the key in and and try to turn it just risks breaking the key the tank.  It has been empty and off the bike for awhile since ive been doing repairs and replacing things and as I'm sure you guys know when you start repairing old things you keep discovering something else that could use replacement or repair  so my bike has been inactive the tank is an original metal OE tank  which id rather not have to find a replacement for. I don't mind replacing the cap if i cant unseize it but if i can fix it all  the better. Either way it has to come off so i can fix and seal the tank.

Thanks in advance for any help.

 



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TTRfan


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I think you just got to soak the lock in WD40 or similar and keep jiggling the key to get the WD around the tumblers etc until it undoes and comes off. The alternative is to drill out the lock barrel no

Once you got it off have a look here to see how to strip out the lock barrel.

Brian



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shad


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I will attempt that tomorrow i really don't wanna drill it out ill let you know if it works

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mossproof


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I didn't think you could turn the cap unless it was unlocked?
Definitely the right key?
I think Brian's right - plenty of wd40, or diesel, and patience.
Good luck,
Simon.

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shad


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cant turn it much and yeah definitely the right key i have them marked with notches in the side 1 notch for ignition 2 and fuel and would diesel work id thought it would be too think or something to get into the mechanism

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ttboof


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Diesel works well the cap will move a bit until the lock tabs hit the tank 



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shad


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Well it took me a bit but i hit it with a crap load of WD40 then worked it off, My tank was a mess tho full of surface rust but tank is cleaned and sealed now i soaked my cap in some rust blast to get the rust off it and it seems to be working fine now still a little bit of rust and corrosion but it should be alright i still got some spare blast if i need it to bad i cant use the sealant on it but that would seize it up big time and WD40 wont help then. You guys got any clue how to get rid of the corrosion on the cap for good maybe soak it in some thick oil or something?
My tank is all shiny and silver now inside aww

 

Thanks for the tip on the WD40 by the way worked a treat.



-- Edited by shad on Wednesday 25th of October 2017 06:04:10 PM



-- Edited by shad on Wednesday 25th of October 2017 06:07:05 PM

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