gas cap seal replacement... how to?

[pennywise]

i have a '77 xs650d just trying to figure out how ones self simply removes the gas cap seal to replace it? please and thank you.

just trying to know how to do it before i actually do it.

 

[chugg]

I have the 78 xs650se, under the cap are two small Phillips head screws that hold the lock mechanism in place. Remove them and take out the lock, which allows the seal and vent to hinge away from the cap. Underneath the vent is a snap ring on the vent shaft, that when removed lets you lift off the vent and seal assembly. There are also three small screws on the underside of the vent that lets you open the vent for inspection and cleaning if so desired.

Philip

 

[jetmechmarty]

i have a '77 xs650d just trying to figure out how ones self simply removes the gas cap seal to replace it? please and thank you.

just trying to know how to do it before i actually do it.

Do you have a new OEM seal or reproduction?

Remove the cap from the tank.

Remove the three screws from the bottom. Now you see that's not what holds the rubber on.

Here is the tech tip from another site:
Special Gas Cap Seal Replacement

I have done this on both the XS1100 and XS650. They are almost identical.

IMPORTANT! When you get this thing apart, you will find a tiny foam vent filter that goes on top of this mess. I am sure yours is rotten. If you do not replace it, you will run out of fuel on the first ride after seal replacement. You will be standing on the side of the road wondering why your bike quit. I have done three of them and I used a tiny piece of Scotch Brite to replace mine.

In the tech tip, they used a radiator cap seal. I keep my bikes, so I went with OEM since they are available. I won't be doing them over.

 

[pennywise]

thanks guys appreciate the help and i will be doing the scotch brite pad thanks

 

[theimbalance]

So I just found this thread when replacing my gas tank gasket. Turns out the PO made the cap tamper proof, and where the 3 screws are it seems to be all soldered together. Do I need to buy a new gas cap? Also, would this be part of the reason my bike will only run on prime or with the choke on? Thanks

1978 xs650 gas cap by davidjohndumais, on Flickr

1978 xs650 gas cap by davidjohndumais, on Flickr

 

[gggGary]

Removing and replacing the clip on the shaft is not trivial.

 

[theimbalance]

Thanks gggGary, I appreciate the input. However, I do not have a clip on the shaft on mine, see pics above.

Worth modifying the gas cap, or should I just replace with yet another order from Mikes?

 

[jetmechmarty]

Why can't you replace the seal? If you need to take it apart, why not remove the solder?

should I just replace with yet another order from Mikes?

Another order from Mike's, or another cap from Mike's? If the Mike's caps are no good, why buy another? I'm sorry, but it seems I don't understand the problem. The link in my earlier post gives you a $2 fix. You're almost there.

 

[theimbalance]

Marty
Thanks for the reply. I didn't mean that I ordered the cap from mikes originally - it was on the bike when I got it. I was just grumbling - I've already spend a bit this year trying to get the bike running and it's now august - feeling frustrated. My apologies for the confusion.

Upon further inspection it's either soldered or riveted together, not fastened with screws as it appears everyone else's is. There is also no clip holding the disc assembly on, it appears to just be threaded on to the tab. Is this model specific?? Thanks all

 

[5twins]

My '78 cap is the same as yours with no screws. Maybe the vent area can't be disassembled on these. No matter, you can still install the thermostat rubber gasket from the link. My local auto parts store lists it as available for $2.99 .....

http://www.autozone.com/autozone/parts/_/N-5yc1s?itemIdentifier=68354

 

[jetmechmarty]

Yes, the radiator car seal is your best bet for now. Just do that. If you run out of gas with a full tank after seal replacement, you'll know you have to address the vent.

 

[Mikey]

Do you have a new OEM seal or reproduction?

Remove the cap from the tank.

Remove the three screws from the bottom. Now you see that's not what holds the rubber on.

Here is the tech tip from another site:
Special Gas Cap Seal Replacement

I have done this on both the XS1100 and XS650. They are almost identical.

IMPORTANT! When you get this thing apart, you will find a tiny foam vent filter that goes on top of this mess. I am sure yours is rotten. If you do not replace it, you will run out of fuel on the first ride after seal replacement. You will be standing on the side of the road wondering why your bike quit. I have done three of them and I used a tiny piece of Scotch Brite to replace mine.

In the tech tip, they used a radiator cap seal. I keep my bikes, so I went with OEM since they are available. I won't be doing them over.

I have a 1975 and can remove the c-clip to get a new cap seal on but is there another seal further inside ?
There looks like there may have been a piece that was there before (as in another seal)
When I take the c-clip off and the gas tank seal off, the 2 metal pieces come apart is that where another seal might be closest to the inside of the tank
part number 308-24641-00-00 ? the schematics from Partzilla are hard to tell what's what
I cant get to my bike for awhile so I can't post a picture right now
Any help would be appreciated

 

[xjwmx]

^Here's a diagram from the site you linked to.
https://www.partzilla.com/catalog/yamaha/motorcycle/1975/xs650b/fuel-tank-tx650a-xs650b

 

[xjwmx]

Actually looks like there might be three gaskets, 5-7.

 

[650Skull]

There was a thread recently about the make up of the cap.........i'll have a look, in the meantime, here is a slightly better visual.

 

[650Skull]

This is the thread but i don't think it will help much
http://www.xs650.com/threads/correct-gas-cap-gaskets-needed-for-1973-tx650.54076/#post-580800

 

[Mikey]

I have a 1975 and can remove the c-clip to get a new cap seal on but is there another seal further inside ?
There looks like there may have been a piece that was there before (as in another seal)
When I take the c-clip off and the gas tank seal off, the 2 metal pieces come apart is that where another seal might be closest to the inside of the tank
part number 308-24641-00-00 ? the schematics from Partzilla are hard to tell what's what
I cant get to my bike for awhile so I can't post a picture right now
Any help would be appreciated

There was a thread recently about the make up of the cap.........i'll have a look, in the meantime, here is a slightly better visual.
View attachment 137236
View attachment 137236

Skull where did you get the better looking visual from ?
I can actually now really see what I need The search is on!! Thanks

 

[Mikey]

Skull where did you get the better looking visual from ?
I can actually now really see what I need The search is on!! Thanks

It looks like I can get OEM parts from a company called OEMPARTZONE (wish me luck) The prices seemed real reasonable but I'm sure shipping will be high as usual
Thanks 650Skull and xjwmx and all the rest of you guys for all your help!!!!!!!!
Hopefully now my gas tank won't leak anymore
One time I left my bike parked in the sun and when I went to move it gas sprayed all over the tank
Evidently the tank got a little warm No fire but it sure was a little scary (from now on I will park in the shade and walk a little)

 

[GLJ]

It looks like I can get OEM parts from a company called OEMPARTZONE

Has anybody ever ordered from this company. They show parts available that nobody else has. For example a gas tank for a XS2 for $183.44. Sounds to good to be true.

 

[Mikey]

Has anybody ever ordered from this company. They show parts available that nobody else has. For example a gas tank for a XS2 for $183.44. Sounds to good to be true.
View attachment 137264

I called the number it said the ??? was unable to answer the phone a the time left them an email asking to talk to a real human being etc.
I just did this today will keep you posted I will not order until I hear back from them