After removing the tank from my 85 K100RS I have been trying to reassemble for several weeks. First I find that there are missing gaskets and seals. I searched high and low looking for kit 16119062461 which has been discontinued by all of the Motorrad dealers I spoke with in Ontario, Michigan and New Jersey. I managed to track one of potentially the only two kits left in the US. I found a very helpful video on YouTube going through the steps to install the kit only to encounter an issue with the center interior nose cone and the corresponding housing. As I don't have a live cap assembly to compare to and no photos or videos I have found show the level of detail I need, can someone please tell me whether or not the interior nose assembly with the latch spring track inside it is press fit into the surrounding housing. Please see the attached photos.

Thank You,

elementalfire

You need 10 posts up before pics can be posted and for this I think you may need them.
It is done that way because we have had problems with spaming. If you PM Crazy Frog and explain he may make an exception but no guarantees.

To get that "nose assembly" off, get a big pair of multigrips and turn the nose anticlockwise...if that doesn't work...turn it the other way. It's been a while and i have forgotten which way it goes. It'll move a centimetre or two before coming apart.

There is a clip on YouTube that shows how to dismantle the fuel cap. Chris Harris is the guy (search on K100 fuel cap rebuild).

For some reason I cannot view the clip here in Oz because it states "This video contains content from SME, who has blocked it in your country on copyright grounds". Mmm, that sucks.

I know there was some change in those gas caps early on so this may not be correct but I think it should be.

My 84RT has 3 screws on the inside of the opening flap, take those out and it comes apart. Wise move is take the whole assembly off so if you drop anything it doesn't end up in the gas tank. You can and should clean out inside the cap, you can access the sprung clip too, remove all the crud etc. I am not sure about the comment about the multi grips and turning the nose, mine was only screwed and came apart easily.

You can also even remove the lock barrel and if your ignition key is not the same as your gas tank key now is your opportunity to key it to the ignition key. ask about that.

When you put it all back make sure the flap opens back towards the rear of the bike so the little drain hole on the left side of the cap is clear. That prevents water getting in your tank.

Hello!

Are you looking for this?

I suppose so.

Cheers

The fuel cap gasket set is available from here
Hopefully they still have them in stock.

A bit of preventative maintenance is needed on the lock/catch mechanism to prevent it from binding. If it jams closed there is a solution here on the forum.

Make sure the water drain hole is not covered or blocked and the cap to tank gasket is sealing otherwise you'llget water in the tank.

Cheers

Chocolate thank you for the lead on the kit. I have one and the video on youtube was of great help. I have the entire cap assembly apart but the interior nose assembly with the track is free of the main housing. Without it being press fit into the housing there is nothing holding the upper portion of the tumbler assembly to the lower nose section. I will appeal to the administrators to see if I a can post photos to make things more clear.

Thank You,

elementalfire

Thank you for the post about Max BMW in New Jersey but they didn't have the kit available when I last spoke to them. There is a gentleman in Germany that supplies some rarer and discontinued parts for BMW bikes. Here is a link to his website https://bmwbike.com/. He is very prompt to reply and according to e-mail correspondence with him he supplies parts directly to customers as well as dealers.

elementalfire

elementalfire wrote:Thank you for the post about Max BMW in New Jersey but they didn't have the kit available when I last spoke to them. There is a gentleman in Germany that supplies some rarer and discontinued parts for BMW bikes. Here is a link to his website https://bmwbike.com/. He is very prompt to reply and according to e-mail correspondence with him he supplies parts directly to customers as well as dealers.

Hi
I believe there are several branches at Max BMW but there is only one who make up an aftermarket kit which I ordered a few weeks ago, followed Chris Harris' YouTube video and successfully rebuilt my gas cap. I believe it was their North Hampton, New Hampshire branch. 

This is the part number 16119062461 $32.50 per kit.

Fuel cap overhaul kit also available from Munich Motorcycles in Australia.

Fuel cap overhaul kit.

Cheers

Now that I am able to post pictures this may be easier to explain. I had managed to get the nose cone cap off previous the issue is with the piece it attaches to. The center portion of the cap assembly popped when I first removed the cap assembly from the tank so now I am trying to determine if that central piece is press fit or potentially and interference fit with out housing. Piece in photo 2 in piece in photo 1.

Where did you get to with this?? I have a similar porblem.. 

J

Which exterior cap design is like your moto's fuel cap, elementalfire?

jayk47 wrote:Where did you get to with this?? I have a similar porblem.. 

You should put your moto's year and model in your signature along with the "learning how to repair the bike I broke . . ." line so it will show up as a reference in every post you make.

Laitch wrote:

jayk47 wrote:Where did you get to with this?? I have a similar porblem.. 

You should put your moto's year and model in your signature along with the "learning how to repair the bike I broke . . ." line so it will show up as a reference in every post you make.

87 k75s. To be fair that line is a gag and the bike is doing all the breaking itself at the moment, I have not had to try too hard! 

I have the fuel cap pictured on the left, 
I assume the one with recessed barrel is an older version.. 

So any advice on the problem??

Laitch wrote:Which exterior cap design is like your moto's fuel cap, elementalfire?

I have Ks with both of these cap types. The right hand one was not used much, it is early type and is on my 'new' K100RS and I have not investigated it. I may leave it as you don't need a key to open this one, you can leave it unlocked. Later ones require the key to open them.

The left hand one I have even on the 84 RT, I have dismantled it and there are 3 screws on the underside keeping the mechanism in place. This one shoul really have a SidecarPaul hole drilled in it.

92KK 84WW Olaf wrote:

Laitch wrote:Which exterior cap design is like your moto's fuel cap, elementalfire?

I have Ks with both of these cap types. The right hand one was not used much, it is early type and is on my 'new' K100RS and I have not investigated it. I may leave it as you don't need a key to open this one, you can leave it unlocked. Later ones require the key to open them.

The left hand one I have even on the 84 RT, I have dismantled it and there are 3 screws on the underside keeping the mechanism in place. This one shoul really have a SidecarPaul hole drilled in it.

Hey Olaf, Thanks for that! still leaves me in the dark a bit on the problem I was having. I ended up gluing the components back together with a two-part epoxy. I may drill the hole to be safe but for now, i am carrying a "pin removal kit" just in case.. I am not sure if i lost a bit or if the filler cap breather just broke. There was not even any sign of glue residue on the parts so i reckon that BMW used some sort of magic to fix the parts together....

My K1100LT also has the three screws on the underside of the cap, remove these and you access everything.

92KK 84WW Olaf wrote:My K1100LT also has the three screws on the underside of the cap, remove these and you access everything.

Hi Olaf. 

Thanks for that. The problem i have had is that the breather nozzle detached from the assembly that is retained by the three screws. see image. There is no way to re attach once this has happened by the looks of things.
 

jayk47 wrote: have had is that the breather nozzle detached from the assembly that is retained by the three screws. see image. There is no way to re attach once this has happened by the looks of things.
 

Please post photos of the top and bottom of the "breather nozzle".

This UTube video may be helpful if you haven't already seen it.

Fuel Cap Rebuild

Cheers

Gaz wrote:This UTube video may be helpful if you haven't already seen it.

Fuel Cap Rebuild

The cap jaky and elementalfire are working on differs from the one in the video.


This is the one jaky and elementalfire seem to be working on.



This is the later and more common model that is in the video.


The top portion of the one that is the subject of this may snap into place similarly to the later model. I'd like to see a photo of the part referred to as the "nose" or nozzle. Olaf might be able to shed some more light on this if he recognizes similarities to one of his caps.

jayk47 wrote:

92KK 84WW Olaf wrote:My K1100LT also has the three screws on the underside of the cap, remove these and you access everything.

Hi Olaf. 

Thanks for that. The problem i have had is that the breather nozzle detached from the assembly that is retained by the three screws. see image. There is no way to re attach once this has happened by the looks of things.
 

This is the one that was on my 84 K100RT and seems to be same on the K100LT and the K1100LT.

I drilled a Paul Sidecar hole and the swarf as Paul said ended up inside the cap. I removed the three screws and took it apart and cleaned it out and while I was at it rekeyed it to the ignition key.

'Breather nozzle' confuses me because I did not find anything attached to the cap. There is a hole on the perimeter of the base plate part to allow water on the tank to drain and as far as I know the 'breather' for the tank is also the over flow pipe that routes down through the tank and out the bottom.

My take was that the area inside under the cover retained by those three screws is completely sealed off from the tank so if you get water in the key hole it cant go in the tank.