Petrol Cap Refurb

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Tornado

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Had a slight weep of fuel from Petrol cap on my HiRider tank. Cap is original as far as I can tell. I've refurbished a cap previously for my Roadster tank. Drilled out the rivet holding sealing plate to cap. Drilled/tapped a thread for a suitable stainless machine screw that was at hand. Removed sealing plate, its rubber seal I believe I may have replaced a few years back, but it looks fine either way. Confirmed sealing plate vent holes are clear.
The short rubber hose under sealing plate, cracked in multiple places and well past its best before decade. It is this bit of hose that applies most of the force to the sealing plate seal against tank neck. Cut a bit of modern fuel hose of similar dimensions, only much stiffer and put all back together.
Scariest part of job is refitting the lid roll pin. I pre-fit it into the lid hinge hole off bike, so that a mm or so protruded on inside of first hinge hole, to help locate on tank neck. Very hard to hold a pin drift, lid and tapping with hammer, first few taps to get it started were without drift.
Thankfully it all went together without much fight. No harm to carefully covered tank paint.

I did notice a paint chip right on the tank neck sealing surface. Likely from a fuel nozzle some time ago. This may be the actual culprit of the wee fuel seep i've seen a couple of time recently. Will see if further action is needed.
 
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