Help! Who knows how to get the latch of a gas cap together

Took it off because I got a new cap but no key, can't figure out how it goes back together. Different style then Len's tutorial.

Any help would be greatly appreciated.

 

I was going to suggest the gas cap writeup, but I see you've got that covered. Now I'm going to have to go look at my 750J and see if it's the same as yours.

 

Re: Help! Who knows how to get the latch of a gas cap togeth

So I got it back together but the piece of the tumbler which actuated the latch is so worn down and the latch is so stiff that I may need to build a new means of actuating the latch when it is closed. was thinking maybe an allen key may work but we shall see.

Thanks all

 

Try and spray some WD-40 in it i did that to mine cause it was squeaky and very stiff and it annoyed me i sprayed in it and the whole back part and soked the springs a bite then dried them with paper towel then i put it back together it helped loosen it up and make it easier to open and close and now there is no noise from it either.

 

Do what arch said, but before for you oil anything, do it this way:

1. take it back apart
2. put a piece of 400 or 600 grit wet/dry sandpaper on a piece of glass
3. LIGHTLY sand/polish the metal pieces to clean smooth surfaces
4. NOW reassemble and lightly lube with PB, Kroil, etc...

A couple of other additional suggestions:

a. work some graphite powder down into the key hole to dry-lube the cylinder.

b. Make sure to replace the rubber seal. I can see a gazillion cracks in your picture. If you don't replace that, you will start having fumes leave the tank, the tank can overflow on a hot day, water can wick into the tank, etc........

So, polish, clean, oil the mechanism, graphite-lube the cylinder, replace the seal, and then.........

No more problem.........pretty much forever.

 

Re: Help! Who knows how to get the latch of a gas cap togeth

This is where the writeup comes in -- unless I miss my guess, the lock plug should be the same as every other XJ gas cap. Follow the instructions to pull it apart, clean and lube the beastie, then reassemble.

As for the latching mechanism, I have no idea about yours -- my '82 750 has the same type of latch as in the writeup. So does my X.

Speaking of which, I need to go pull that cap apart so I can take some pictures to update the file. Len has parts available now that weren't before (like those teeny-tiny wafer springs).

 

Re: Help! Who knows how to get the latch of a gas cap togeth

The center of your locking mech, the post on the right side in your pic, looks to be much shorter than it should be.

This may be why it's stiff/not turning the bolt.

Look at the write up in my signature on how to pull everything apart and replace with the old mech, if you still have it.

This will allow you to use the key for the old cap, but put the guts into the new lock tumbler.

EDIT: Yes, the write up is for an ignition, but once you get to the steps where the tumbler is out of the switch, changing parts are the same for the gas cap. I did the same thing with my cap but didn't do an actual write up on it, since it was the same basic principal.

 

Re: Help! Who knows how to get the latch of a gas cap togeth

Got it all fixed up for now.

She does need an overhaul but there are a few issues with the bike and I just want to get it going so I can make my grocery list before rebuilding and replacing all the worn and cracking parts.

Thanks again