Here is a guide for removing your old fuel cap and installing a new one. Obviously, there are going to be differences between models and/or the caps themselves, but the basics remain the same. Most of the effort is common sense, but there are a couple tips that might save someone a couple hours of effort taking care of a mistake made along the way. It is not a complicated process and shouldn't require more than your set of allen wrenches, Q-tips, WD-40, a little grease and about 10 minutes if you are in a rush. I went slow, took some pictures along the way and start to finish, took just under 20 minutes.
As with any time you are working with gasoline, do so in a well ventilated area. Disconnect your battery, do not use tools that generate a spark, turn off all pilot lights in your work area and don't smoke. If you can't follow simple safety precautions, don't do it. This is intended as a guide. I am not responsible for any mistakes made or damage done.
Thanks to the guys at MotoWheels, my 749S will be graced with a Ducati Performance CF Gas Cap. The Parts,
the Bike,
and the old cap.
Unlock the old cap and spend a couple minutes with some Q-tips and WD-40 cleaning out the dirt that collected under the old cap. Do not remove the old cap yet, as it helps provide a barrier against pushing dirt into the tank.
Put some masking tape over the open hole and start taking the screws out. The tape will prevent screws and allen wrenches from dropping into the tank. Simple tip, but common sense.
Once the screws have been removed, gently lift the entire cap assembly out of the tank and spend a few more minutes cleaning the recess with Q-tips. Always work dirt away from the open hole. Chances are there is already enough gunk in the tank from filling up at the local pump.
Get the fuel cap mounting plate ready and put the gaskets on the plate. I put a dab of grease on the gasket for the breather to keep it in place during assembly.
Here's where I could have done something slightly different. Instead of putting another piece of tape over the hole in the mounting plate,
I could have simply put the cap on the plate to cover the hole while screwing it down.
Regardless of which way you cover the hole, tighten the screws in a star pattern, a half-turn at a time. This ensures the gaskets seat properly and do not kink.
Before you put the cover in place and fasten it down, take the bike off of your stands and rock it side to side a couple times. Rock it hard and get the fuel sloshing around. You are checking to see whether the gaskets sealed properly. The last thing you want is for gas to leak out and on you or a hot engine. Refer to the above picture.
Pull the tape if necessary, put the cap on, sit back and admire the fruits of your labors.
Looks sharp, doesn't it?
Charles
Linear Mode
