Author Topic: '03 Stone Gas Cap DOA  (Read 304 times)

Offline NC Steve

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'03 Stone Gas Cap DOA
« on: July 14, 2019, 04:22:43 PM »
I recently acquired an '03 Stone Hydro, and set about yesterday to removing the gas cap and do the Dremel trick to remove some material and prevent it from swelling and getting stuck. Well guess what, it's already stuck, on my first attempt to remove it. I've tried using WD-40, following some You Tube video ideas that didn't work, etc. I've worked on it for 2 days, and if I could just get the key to turn one time, I could take it and fix it. Having had a Jackal in the past, I know the procedure.

Does anyone have any ideas of how I can get the cap off? I've searched here and found plenty of posts about fixing the cap if it's off, but nothing on removing one already stuck. And if not, will drilling or punching out the lock release the mechanism inside so that I can get it off? I hate to do that, but if it's my only option, new locking caps without the plastic parts are available. :cry:
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
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Online Wayne Orwig

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Re: '03 Stone Gas Cap DOA
« Reply #1 on: July 14, 2019, 05:03:09 PM »
Can't you just take the screws out of the ring, or am I thinking of something else?
Scientist have discovered that people will believe anything, if you first say "Scientist have discovered...."


Online Gusable

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Re: '03 Stone Gas Cap DOA
« Reply #2 on: July 14, 2019, 05:09:27 PM »
My 98ís stuck recently. I kept putting kroil in and around the cap. Finally got it opened.  I think in the key slot itís going to get into the sticky areas. Itís ď the oil that creepsĒ they say.  Worked for me
1998 v11 EV

Online StuCorpe

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Re: '03 Stone Gas Cap DOA
« Reply #3 on: July 14, 2019, 06:09:42 PM »
I second the use of Kroil.  Worked on mine.

Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #4 on: July 14, 2019, 07:06:14 PM »
Just ordered a can of Kroil, sure hope it works. I wish they sold it in something smaller than a 10 oz can, but I'll probably find more uses for it over time. I'm keeping my fingers crossed that it'll solve the stuck cap problem!
Thanks.  :thumb:
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


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Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #5 on: July 14, 2019, 07:15:36 PM »
Just ordered a can of Kroil, sure hope it works. I wish they sold it in something smaller than a 10 oz can, but I'll probably find more uses for it over time. I'm keeping my fingers crossed that it'll solve the stuck cap problem!
Thanks.  :thumb:

Oh, you will.. Kroil is great. But.. isn't Wayne right about taking the ring off? <scratching head>
Chuck in (Elwood) Indiana/sometimes SoCal

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Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #6 on: July 14, 2019, 07:21:57 PM »
Oh, you will.. Kroil is great. But.. isn't Wayne right about taking the ring off? <scratching head>

I'm not certain about removing the ring. Several sources I found said that the screws easily fell into the tank, and I'm also unsure about what is on the other side of the ring. Even if I removed it, would the cap not still be stuck, due to the ethanol-swollen plastic?
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


___________________ ___________
Be kinder than necessary. Everyone you meet is fighting some sort of battle.

Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #7 on: July 15, 2019, 06:21:25 AM »
I'm not certain about removing the ring. Several sources I found said that the screws easily fell into the tank, and I'm also unsure about what is on the other side of the ring. Even if I removed it, would the cap not still be stuck, due to the ethanol-swollen plastic?

Memory is a funny thing when you're old.. :rolleyes:  but its seems to me that there are cast in nuts in the tank. Once you have the whole assembly out, you can knock out the pin and disassemble the lock. (I think?) <shrug>
Chuck in (Elwood) Indiana/sometimes SoCal

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The trouble with the world is that the stupid are cocksure and the intelligent are full of doubt.' - Bertrand Russell

Online Ncdan

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Re: '03 Stone Gas Cap DOA
« Reply #8 on: July 15, 2019, 07:29:31 AM »
Maybe not for their particular situation but I had a cap get stuck on a 03 EV. After I got it to finally unlock and removed it and got everything loosened up from that point on every couple weeks I would coat the key with good machine oil and run it and out of the gas cap and switch. I do that with every bike I owned for several years now and never had another issue. 

Online Mike Tashjian

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Re: '03 Stone Gas Cap DOA
« Reply #9 on: July 15, 2019, 07:31:02 AM »
I just looked at my Stones gas cap and I think the whole thing comes off with the five screws like Wayne says.  Chuck's memory seems good this morning as the cap has a small pin holding the guts of the cap together.  There is a shield extending into the tank to prevent over filling which, may be close to interfering with the pin removal.  But that shield may release with the removal of the whole assembly. I can't see how you could drop the screws into the tank.  I can't see how loose nuts could be used either, on the inside of the tank.   Mike

Offline nsmith

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Re: '03 Stone Gas Cap DOA
« Reply #10 on: July 15, 2019, 08:20:41 AM »
take out the tank screws, now you can spray whatever you like directly on the offending parts. I don't think you can disassemble the lock until you get the cap away from the locking ring but at least you can lube the lock much easier.
Neil formally from South Dakota now living it up in Arkansas

Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #11 on: July 15, 2019, 08:26:20 AM »
take out the tank screws, now you can spray whatever you like directly on the offending parts. I don't think you can disassemble the lock until you get the cap away from the locking ring but at least you can lube the lock much easier.

Thanks, that's what I was just thinking. I don't doubt that the cap will remain stuck in the ring, but if I can lubricate both sides maybe I can at least get the cap out so I can disassemble it and file down the swollen plastic.
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


___________________ ___________
Be kinder than necessary. Everyone you meet is fighting some sort of battle.

Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #12 on: July 15, 2019, 10:55:39 AM »
Turns out that in addition to the 5 screws, the ring is also held in place by the cap itself. So, it is loosened and able to spin, but can't be removed while the cap is in place, and that's still not willing to budge.

Back to waiting for the Kroil to arrive...
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


___________________ ___________
Be kinder than necessary. Everyone you meet is fighting some sort of battle.

Online Wayne Orwig

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Re: '03 Stone Gas Cap DOA
« Reply #13 on: July 15, 2019, 10:58:53 AM »
Turns out that in addition to the 5 screws, the ring is also held in place by the cap itself. So, it is loosened and able to spin, but can't be removed while the cap is in place, and that's still not willing to budge.

Back to waiting for the Kroil to arrive...

Dang. Hoped that helped. Maybe at least with the ring off you can get some lube down in around it.
Scientist have discovered that people will believe anything, if you first say "Scientist have discovered...."

Online BrotherJim

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Re: '03 Stone Gas Cap DOA
« Reply #14 on: July 15, 2019, 01:03:40 PM »
Cap was stuck on my '02 CalStone when I bought it.  I fired some brake or carb cleaner from an aerosol down into the keyhole, holding a towel around it to protect the paint.  After the cleaner stopped coming out gritty and black, I dried it out with a couple quick shots from the air compressor (again with the towel) and used a bit of Kroil in the keyhole as others have mentioned.  Voila!  No doubt you remember the key turns counter-clockwise.  :wink:
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Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #15 on: July 15, 2019, 01:04:46 PM »
Turns out that in addition to the 5 screws, the ring is also held in place by the cap itself. So, it is loosened and able to spin, but can't be removed while the cap is in place, and that's still not willing to budge.

Back to waiting for the Kroil to arrive...
<scratching head> Man, that just doesn't sound right.. you'd think the cap and ring assembly would be removable from the tank itself..
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
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The trouble with the world is that the stupid are cocksure and the intelligent are full of doubt.' - Bertrand Russell

Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #16 on: July 15, 2019, 01:17:25 PM »
The 5 screws hold the ring to the tank, but the cap goes thru the ring, and its locking mechanism inside the tank is holding everything together. If the cap is locked into the tank, nothing can be removed.  :undecided:
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


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Be kinder than necessary. Everyone you meet is fighting some sort of battle.

Online john fish

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Re: '03 Stone Gas Cap DOA
« Reply #17 on: July 15, 2019, 01:49:47 PM »
Great stuff from a Guzzisti:  https://theboxjunkie.com.au/

Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #18 on: July 15, 2019, 02:36:19 PM »
Best penetrating oil is ATF and Acetone mix:

https://oppositelock.kinja.com/make-your-own-kick-ass-penetrating-oil-1739690558

It's *the* best for rust, but not necessarily best for corrosion.
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
The trouble with the world is that the stupid are cocksure and the intelligent are full of doubt.' - Bertrand Russell

Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #19 on: July 15, 2019, 02:40:45 PM »
The 5 screws hold the ring to the tank, but the cap goes thru the ring, and its locking mechanism inside the tank is holding everything together. If the cap is locked into the tank, nothing can be removed.  :undecided:
It just doesn't make sense. (of course it's Guzzi we are talking about :smiley: but still..) If I were designing a tank to be molded, I'd cast the nuts in place, and the ring would hold the cap. The locking gizmo (technical term) on the cap shouldn't be locking on the plastic tank..
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
The trouble with the world is that the stupid are cocksure and the intelligent are full of doubt.' - Bertrand Russell

Online drdwb

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Re: '03 Stone Gas Cap DOA
« Reply #20 on: July 15, 2019, 02:56:02 PM »
The locking gizmo (technical term) on the cap shouldn't be locking on the plastic tank..
Chuck your fingers  may have been faster than your memory, at least on  My wifeís 03 -04 Stone the tank is metal, not plastic.
07 Norge, 05 Baby Breva, 04 Stone  Touring , 03 EV, 82 650 Maxim 79 XS750 Special 78XS1100 Teraplane side car

Online Mike Tashjian

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Re: '03 Stone Gas Cap DOA
« Reply #21 on: July 15, 2019, 03:33:39 PM »
Looking closer at my Stone the ring with five screws is more trim than function.  The inside part where the cap keys into position looks to have another set of screws that holds that part to the tank.  And it looks like the cap and trim ring must be removed to get to them.  So the keys shoulder looks like it goes into the tumbler far enough that some pressure can applied to turn it once the lube loosens it a bit.  More of pain than it should be for sure.  Sure glad I trimmed my cap up years ago.    Mike

Offline Chuck in Indiana

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Re: '03 Stone Gas Cap DOA
« Reply #22 on: July 15, 2019, 03:35:58 PM »
Chuck your fingers  may have been faster than your memory, at least on  My wifeís 03 -04 Stone the tank is metal, not plastic.

Ahhhh.. my bad. I don't know why I was thinking plastic tank..  :rolleyes: Thanks for setting me straight. <head down and shuffling off..>
Chuck in (Elwood) Indiana/sometimes SoCal

02 Scura RC
87 AeroLario
79 G5
95 Skorpion tour
 
The trouble with the world is that the stupid are cocksure and the intelligent are full of doubt.' - Bertrand Russell

Offline yogidozer

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Re: '03 Stone Gas Cap DOA
« Reply #23 on: July 15, 2019, 03:53:27 PM »
When you finally get that POS off, beat it with a sledge hammer until you can't lift it any more.
Then contact member swbrenton, he made me a beautiful cap w/o the lock.
Never had a bit of trouble with it.

Offline NC Steve

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Re: '03 Stone Gas Cap DOA
« Reply #24 on: July 15, 2019, 06:35:44 PM »
When you finally get that POS off, beat it with a sledge hammer until you can't lift it any more.
Then contact member swbrenton, he made me a beautiful cap w/o the lock.
Never had a bit of trouble with it.

That's what my plan is if I can't soon get the thing off. A 3 lb. hand sledge should work great!
And I remember those caps, they were beautiful, but I'd like a lock though, if it wasn't plastic.

I may just spring for one of these, from MG Cycle.
http://www.mgcycle.com/index.php?main_page=product_info&cPath=286&products_id=2254
« Last Edit: July 15, 2019, 06:38:38 PM by NC Steve »
'03 Stone Hydro
'99 BMW R1100R-traded
'19 Royal Enfield Himalayan-love it!
'89 Guzzi Mille GT-sold
'07 Honda ST1300-gone
'00 Guzzi Jackal-sold
Several BMW Airheads and a K75


___________________ ___________
Be kinder than necessary. Everyone you meet is fighting some sort of battle.

Offline yogidozer

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Re: '03 Stone Gas Cap DOA
« Reply #25 on: July 15, 2019, 06:44:03 PM »
That looks like the EV one. I did the grinding down thing, worked OK for awhile. But then acted up again.
I don't have my bike out of my sight much, and almost always a tank bag covering it.
Maybe you should ask others if they have used that cap?

Online Wayne Orwig

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Re: '03 Stone Gas Cap DOA
« Reply #26 on: July 15, 2019, 06:54:36 PM »




2004 EV
Take out the screws, pry off the ring, and the locked cap comes off with it. You can then do surgery on it.

The ring IS a tight fit against the paint lined hole, so it will not just flop out.
Scientist have discovered that people will believe anything, if you first say "Scientist have discovered...."

Online Rich A

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Re: '03 Stone Gas Cap DOA
« Reply #27 on: July 15, 2019, 07:06:00 PM »
BTW, the gasket for the tank ring is ridiculously expensive. Be careful with it.

Rich A

Online jcctx

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Re: '03 Stone Gas Cap DOA
« Reply #28 on: Today at 09:57:56 AM »
When you finally get it apart~ just dremel the bottom coil off the big spring. Worked like a charm; takes couple minutes!!

 

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