Stuck gas cap on 2002 Cali.

[actwin]

My gas cap on my 2002 Special Sport will not come out. The key goes in fine but the cylinder won't turn. The key works on the helmet lock like nobodies business. I have tried wiggling it  and it moves around but it wont turn.  Previous owner never had an issue and I believe him, he's too good a person not to have told me about it. I'm gonna try some wd40 and cross my fingers. Any ideas?

[kballowe]

Spray it all around the outside edge with WD-40.  They get dry and stuck.

Leave it sit a little bit.  Press around on it some.  It'll loosen up.

[Mackers]

http://motoguzzimaintenance.wikifoundry.com/page/Moto+Guzzi+California+Fuel+Cap

[pehayes]

There is a central, plastic piece that expands and binds.  It can be carefully sanded to work better.  There is a replacement cap with that same piece in metal to eradicate the problem.  MG-Cycle or Harper's should have it.

Patrick Hayes
Fremont CA

[John A]

don't destroy the cap, getting it off. take out the allen screws, then with a very thin pry bar break loose the cap from the tank. don't hurt the rubber seal, I like to use old butter knives with good steel in them.  then you can have your way with the underside of the cap.

[Guzzidad]

   I recently bought an 02 Special Sport and the previous owner included the kit with the metal internals that he got from Harper's. I installed it and it works great.

[et18]

This won't fix your gas cap but it will give you something to read while you wait for parts.  I was looking for an original comparison with a BMW R1200C and came across this.  I was really looking forward to reading about how the '02 Cali compared to the R1200C and several other 1100 / 1200 cruisers, but the Cali got left at the first gas station due to a stuck gas cap.

My 1200C? It lost a turn signal lens somewhere during the test, a common problem.

https://www.motorcyclecruiser.com/tweener-twins-1100-and-1200cc-motorcycles-compared/

[Ncdan]

Try real hard to not break the key off inside the cap.
+1 on soaking every place you can get to with WD40. When the key is in the cap you can use the straw to spray WD easily into the cap, as the little flap and s open then, work it slowly back and foreword until it releases from the tank.

[LowRyter]

I trimmed the little plastic piece with a pocket knife. 

[SteveRivet]

I had to do the same mod to my Bassa after a few years.  Surprised yours is just showing the behavior now.
-Steve

[jcctx]

Had same issue on an EV; when I finally got it out I cut a coil off the spring. Never an issue afterwards. YMMV???

[john fish]

I trimmed the cap on my Jackal. It’s been fine for a few years but it’s starting to feel like it might need a bit more trimming.

I put this on my Stone to permanently fix the problem.







I forget the name of the gentleman who made those but I’m betting that someone here knows.  The Stone came with a good replacement cap but I didn't like having to carry a different key for the cap.

[actwin]

Are we allowed to cuss on here? I finally got the sumb#tch out. The wd40 did nothing as far as I could tell. I had to put the key in a vice and pull on the cap to get the key out. Im not sure its gonna go all the way in again. Now to take the sumb#tch apart. Thanks for all the info guys, its so good being a Guzzi owner again. It's so good being a Guzzi owner again. Its so good being a Guzzi owner again. There I think I believe myself, now.

[Antietam Classic Cycle]

I trimmed the cap on my Jackal. It’s been fine for a few years but it’s starting to feel like it might need a bit more trimming.

I put this on my Stone to permanently fix the problem.







I forget the name of the gentleman who made those but I’m betting that someone here knows.  The Stone came with a good replacement cap but I didn't like having to use carry a different key for the cap.

Stephen Brenton made those, but he has since retired and is traveling around the country now.

[john fish]

Thanks, Charlie.  I just can never remember the gentleman's name.  I like it and wish someone would make some more.
Anyway, the repair on your cap is pretty easy, actwin.  I'm clumsy but I had it done in less than an hour.

[Vagrant]

FWIW Try this stuff next time. I tossed all the other lubes away after getting it. Lowes has a good price. Ace usually has it but it might not be $8. there.
http://www.superslickslickstuff.com/

[actwin]

Ta DAAAA! I got it fixed and went for a ride. Short one cause I don't have a plate for it yet but long enough to hear the clutch slipping in 5th gear. Ah Guzzi life! It wont idle either.

[Tom]

Actwin look at my thread  https://wildguzzi.com/forum/index.php?topic=107868.0  Print out a couple of eagles to keep your sense of humor when you run into another common problem.  BTDT on my Jackal. 

[Ncdan]

Y’all got me a little skeered over this gas cap issue so I addressed mine to prevent future possible issues.
I have some super good firearm lube that penetrates metal or any other material and put it on the surface of the plastic where it meets the metal. Now it’s slick as a whistle 👍👍

[Tom]

No petro chemicals in it right???  Otherwise it might stick later.

[Ncdan]

No petro chemicals in it right???  Otherwise it might stick later.

I don’t think so Tom, some kind of teflon based material. Thanks for the heads up and I’ll definitely pay close attention to it daily until I can determine if it’s going to create an issue worse that normal.
Thanks Tom.

[Tom]

Use that non-petro lube on your linkages too.  Saves a lot of headaches.

[s1120]

That was the first repair I did on the new to me 02 stone I got a few years ago. No issues at all since, but I still think it will stick every time I go to put the key in it!

[Calidavid]

I had the same issue on my EV. DO NOT used WD40. It reacts with the plastic. Use silicon grease. That sorted mine out.

[kballowe]

I've not had a problem with WD-40 and anything.  I buy it by the gallon.

I might be missing something here, but isn't gasoline a "petroleum product"  ?


...According to the WD-40 manufacturer....

For all variations:
WD-40 Multi-Use Product demonstrates none to negligible deleterious effect to plastic, rubber and metal hard surfaces.

This includes Acetal, neoprene/hard rubber, HDPE, PPS Copolymer Polysulfone. Teflon, Viton, steel, galvanized steel hot dip, electroplated, copper, brass, magnesium, nickel, tin plate, titanium and zinc.

SURFACE CAUTIONS:  Nearly all surfaces interact with WD-40 Multi-Use Product as they would any high grade aliphatic petroleum spirit. Certain types of rubber will swell upon prolonged immersion. Wax polishes and certain wax coatings may be softened by WD-40 Multi-Use Product. Clear polycarbonate and polystyrene may stress craze or crack. Always test surfaces first.

[Calidavid]

WD 40 problem.

I don't know the chemical make up of these things but I was advised by my extremely experienced Guzzi engineer not to use it in these circumstances. I am sure that it is not a lubricant in any case. The lock certainly felt very abrasive when I did whereas the silicon grease sorted the problem.

[Ncdan]

I think, for me anyhow, I fixed and future problems of this nature on my 02 gas cap.
If you remove the cap and turn the action, a small gap appears between the metal and plastic part.
The gap is enough for a sheet of sandpaper to be pulled through it. I used a 80 grit piece and pulled it through both sides of the cap several times on both the plastic and metal part. After placing in cap back on the tank, the key turned and released the cap much smoother, taking much less torque on the key to unlock the cap. I then applied a thin coat of silicon grease in between the two parts. The cap removes smooth and easy.