Author Topic: Fuel Cap Repair/Rebuild ( ST1100 ) *  (Read 10716 times)

Offline KoTAOW

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Fuel Cap Repair/Rebuild ( ST1100 ) *
« on: August 28, 2008, 07:33:36 PM »
Contributed by Don Grimes, STOC #1285.

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Fuel Cap Repair/Rebuild ( ST1100 )

If you are having a fuel cap problem with the valve sticking and tank not venting then no need to buy a new Fuel cap as they are expensive and your old one can be rebuilt. This procedure isn't in the service manual.
 
1. Note that there are orientation marks on the top of the cap (white paint dot) and an indentation on the edge of the cap. Before starting to disassemble mark the bottom side of the cap with a scribe line aligned to the indentation on the edge so cap can be reassembled in same orientation.
 
2. Use a pair of needle nose pliers to unroll the edge of the bottom of the cap and separate the cap.
 
3. At disassembly there will be three parts, top, inside and bottom.
 
4. The inside part will disassemble into several parts to reveal the valve and spring etc. There are O-rings also. None of these parts can be bought separate from Honda.
 
5. Upon breakdown I found I had a lot of orange gooey, sticky fuel residue on all the parts that kept the valve from operating properly. Use lacquer thinner to cut and remove the residue and start reassembly.
 
(part 1 of 2)
« Last Edit: January 04, 2013, 04:35:10 PM by Tom Melnik »

Offline KoTAOW

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Re: Fuel Cap Repair/Rebuild ( ST1100 )
« Reply #1 on: August 28, 2008, 07:34:56 PM »
I took some pics left to right of how the cap disassembles and have labeled them starting at Nr. 1.
 
6. Reassemble the inside section first (the one with the valve) then insert it in top and install the bottom. When reassembling keep pressure on the bottom piece when you roll down the edge of the top so that all the O-Rings will seal etc.
 
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Thank You again for your contribution Don Grimes, STOC #1285
« Last Edit: May 21, 2012, 07:38:13 PM by KoTAOW »

Offline KoTAOW

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Re: Fuel Cap Repair/Rebuild ( ST1100 )
« Reply #2 on: March 29, 2009, 02:21:58 PM »
Original article can be viewed here:
http://home.insightbb.com/~mmartin36/Gascap.htm

Submitted by Mike Martin.

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Gas Cap Fix

Over time, the gas cap gets harder and harder to unscrew. Obviously, some lubrication will make it easier, but simply applying some grease to the face of the gas cap gasket seems to help for only a short while.

The trick is to apply the grease to the upper surface of the gasket, the surface that contacts the gas cap. Try it, you will be surprised how much better this works.

2002 M. E. Martin, All rights reserved