New member, and fuel tank cap o-ring... - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 1Likes
  • 1 Post By DannoXYZ
 
LinkBack Thread Tools
post #1 of 14 (permalink) Old 9-5-2019, 5:08 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Location: Sacramento, CA
Posts: 4
 
Hi. Looks like a wealth of (current) info here. I've been spending the last few weeks getting an '87 EX500 running again after a long time sitting.

I had the gas tank off, then removed the cap assembly for cleaning. Removed the o-ring (with the spring-loaded ring), but now it won't stay back on. I suspect it's because it's hard and maybe enlarged, but did I miss something that holds it together?

Btw, tried to access (mobile) this https://www.ex-500.com/index.php/topic,15477.0.html but got the message "You don't have permission...". I'll try it on a computer.

Thanks. Sorry if I'm wordy!

Last edited by stevet; 9-5-2019 at 5:11 PM. Reason: Remove Emoji's
stevet is offline  
Sponsored Links
Advertisement
 
post #2 of 14 (permalink) Old 9-5-2019, 5:18 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
Welcome🏍

I just tried to click on that link you put up and it said it was an invalid something or another. Don't know what is up with that.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #3 of 14 (permalink) Old 9-5-2019, 5:25 PM
Senior Member
 
jorge moros's Avatar
 
Join Date: Nov 2014
Posts: 775
 
Welcome!

And what @bpe said.

May be, if you put some pics, someone with the expertise required will chime in.

Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -Albert Einstein.
2007 Ninja 500R
jorge moros is offline  
post #4 of 14 (permalink) Old 9-5-2019, 7:58 PM
Senior Member
 
Join Date: Oct 2017
Location: S.F. Bay Area
Posts: 197
 
That's Key Hole is Not Tank Vent thread. Got some good photos in that one.

Last edited by DannoXYZ; 9-5-2019 at 9:55 PM.
DannoXYZ is offline  
post #5 of 14 (permalink) Old 9-5-2019, 8:38 PM
Senior Member
 
Join Date: Oct 2017
Location: S.F. Bay Area
Posts: 197
 
Quote:
Originally Posted by stevet View Post
I had the gas tank off, then removed the cap assembly for cleaning. Removed the o-ring (with the spring-loaded ring), but now it won't stay back on. I suspect it's because it's hard and maybe enlarged, but did I miss something that holds it together?
can you post photos of these parts that's not going back together?
DannoXYZ is offline  
post #6 of 14 (permalink) Old 9-5-2019, 8:48 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
If your referring to the rubber ring with the tab on the end, are you sure it isn't in upside down?

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #7 of 14 (permalink) Old 9-6-2019, 1:22 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
See if there is anything here that will help. https://www.ex-500.com/37-how-s-fyi/...r-gas-cap.html

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #8 of 14 (permalink) Old 9-10-2019, 1:44 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Location: Sacramento, CA
Posts: 4
 
Thanks for all the (prompt!) replies. I've had to tend to things for my 89yr old mom, but I did have a chance to take a look at the links, and the photos were great.
My '87 EX500 cap assembly is different from those in the photos. There's a brass ring with 5 tiny springs underneath (looking from below) which slides down over the lock cylinder...
(posting is difficult from my phone. I'll get to a computer to finish it and add some photos also) thanks again to all who replied.
stevet is offline  
post #9 of 14 (permalink) Old 9-10-2019, 3:11 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
Quote:
Originally Posted by stevet View Post
My '87 EX500 cap assembly is different from those in the photos. There's a brass ring with 5 tiny springs underneath (looking from below) which slides down over the lock cylinder...
I don't know if the gen1 (your bike) cap is the same as the gen2 (example in photos). But the gen2 (in the photos) does in fact have the brass ring with 5 tiny springs underneath (looking from below) which slides down over the lock cylinder.

Edit:
In the link I provided, picture #12 (counting from the top down) shows this brass ring. And with an arrow pointing to it. You can also see 2 of the springs underneath it.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Last edited by bpe; 9-10-2019 at 3:29 PM. Reason: Pic info
bpe is offline  
post #10 of 14 (permalink) Old 9-11-2019, 5:49 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Location: Sacramento, CA
Posts: 4
 
Quote:
Originally Posted by bpe View Post
I don't know if the gen1 (your bike) cap is the same as the gen2 (example in photos). But the gen2 (in the photos) does in fact have the brass ring with 5 tiny springs underneath (looking from below) which slides down over the lock cylinder.

Edit:
In the link I provided, picture #12 (counting from the top down) shows this brass ring. And with an arrow pointing to it. You can also see 2 of the springs underneath it.
@bpe thanks for pointing that out! In my case, I don't yet know if there are any venting problems, so I didn't remove the latch assembly (have done now), and missed the details of photo #12.

My problem (gas cap, lot's of other problems with me), I think, is simply that the plasticizers have left my fuel tank seal, so it's hardened over the (30+) years. I can probably just buy or make one, but I can't resist the temptation to try to restore the rubber myself (would be useful for other parts on my old bike) -- found videos that show use of a solution of methyl salicylate (wintergreen), alcohol, and sometimes dimethicone to restore plasticity.

A question:
Photo #5 ("Remove the outer ring..."): Is your thumb bending the flap/tab, you refer to in post #6? Hmmm, mine doesn't have one -- maybe it was replaced by the shop I had taken it to (one time many years ago) to balance the carbs.

Thanks again for your help. Some photos of my stuff...
Attached Images
File Type: jpg ex500_fuel-cap-4.jpg (352.9 KB, 6 views)
File Type: jpg ex500_fuel-cap-2.jpg (279.7 KB, 4 views)
File Type: jpg ex500_fuel-cap-1.jpg (416.2 KB, 4 views)
stevet is offline  
post #11 of 14 (permalink) Old 9-11-2019, 7:47 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
Quote:
Originally Posted by stevet View Post

A question:
Photo #5 ("Remove the outer ring..."): Is your thumb bending the flap/tab, you refer to in post #6? Hmmm, mine doesn't have one --
That is correct.
Here is what I have found:
The original gen1 cap part# is 51049-1091
The original gen2 cap part# is 51049-1130

So they would not be exactly the same. You don't have that rubber piece, and I can see in your first pic the rubber seal that it replaced. Thanks for posting the pics. My guess is, this is going to be the only difference between the two different generations.

Side note:
Also both the gen1 & gen2 caps have been superseded by part# 51049-0018. This, the only replacement OEM cap available has been the replacement part even when the bike was in production. This cap doesn't even have a lock on it.

Looks like the only part you can get new (other than the entire cap) is the rubber gasket in my pic# 4.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #12 of 14 (permalink) Old 9-12-2019, 4:17 AM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,564
 
Garage
Quote:
Originally Posted by bpe View Post
Here is what I have found:
The original gen1 cap part# is 51049-1091
The original gen2 cap part# is 51049-1130


Side note:
Also both the gen1 & gen2 caps have been superseded by part# 51049-0018. This, the only replacement OEM cap available has been the replacement part even when the bike was in production. This cap doesn't even have a lock on it.
Update:
After digging deeper it appears I was misinformed by my dealer some years back. Part# 51049-0018 is an original cap used on '07 - '09. (with a lock) To sum up there are 3 different caps.

51049-1091 for '87 - '94 (including the first gen2 year)
51049-1130 for '95 - '06
51049-0018 for '07 - '09

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #13 of 14 (permalink) Old Yesterday, 5:27 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Location: Sacramento, CA
Posts: 4
 
Wow, I'm blown away 🙃🏍️ Thanks for the part #'s. Curious what resource(s) you use... dealer, database? Thanks again!

I think I'm getting close to getting her running -- cleaned up carbs, fuel tank (funny story about that one - I'll have to tell it in a new thread); new oil, filters, plugs. I suspect I might have used too much fogging oil, though...
stevet is offline  
post #14 of 14 (permalink) Old Yesterday, 7:19 PM
Senior Member
 
Join Date: Oct 2017
Location: S.F. Bay Area
Posts: 197
 
You can go to any parts site such as http://ronayers.com

Then enter in your make/year/model and scan through various parts-diagrams. Click on specific area of interest and you get diagram and part#
https://www.ronayers.com/oemparts/a/.../fuel-tank-2-3

To find variations and changes over time, re-enter make/year/model and see if part# is same or changed.

'95 - https://www.ronayers.com/oemparts/a/...-tank-ex500-d2
'07 - https://www.ronayers.com/oemparts/a/.../fuel-tank-2-6
crackerwitbeans likes this.
DannoXYZ is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome