Servicing your gas cap - - The home of the Kawasaki EX500 / Ninja 500R
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  • 1 Post By ducatiman
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  • 1 Post By K-woppa
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post #1 of 4 (permalink) Old 9-6-2019, 1:55 PM Thread Starter
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Servicing your gas cap

Cleaning, removing vent, and reassembly references

Tools required:
#1 Phillips screwdriver (JIS would be better)
4mm hex socket (or Allen wrench)
Needle nose pliers

Open the gas cap and remove the anti-theft screw.

Then remove the 7 hex screws attaching the cap to the tank.

Do not use a vacuum or compressed air to clean this area.
Rag wiping only.

Cover the tank hole to prevent debris from entering.

Remove this rubber gasket and clean.

Remove the outer ring by removing these 2 screws.

Remove the latch assembly. (2 screws)

Remove the 4 screws holding the vent and lock cylinder assembly in place, and pull apart.
Note: The arrow indicates the area where a small rubber vent was in place. ( but is long since gone on my bike) If this is still in place you will want to remove and discard it. This is the main (if only) culprit in poor ventilation with the tank.

You can lift the rubber vent container out with a pair of needle nose pliers.

Underneath you will see another rubber vent. Most members will go ahead and remove this one also. I have left mine in place. Each rubber vent goes to a separate venting circuit. One vents in, and one vents out. Once the top vent valve is removed, it will vent both directions through the one circuit. (Assuming the circuit itself isn't clogged)

Underneath the lock cylinder there is a cardboard type gasket to remove. ( Carefully as to not damage it)

There you can see the 2 vent circuits. These are looking perfectly clean and clear. It has been reported that these can get corroded and clogged, thus in need to be cleaned for proper ventilation.

Once it is cleaned and the vent valve (or valves) have been removed, your ready for reassembly. Reassembly is in the reverse of assembly.

Reassembly notes:
All screws and hex screws just get tightened slightly snug.

Make a note the direction the rubber gasket, and metal spring ring go.

There are 2 small spring loaded hollow pins here. Make sure these are in place. This is the pivot point for the key hole lid.

Make sure there are 2 ball bearings and 2 springs here. These need to be in place for proper key hole lid operation.

Careful during disassembly. These springs and bearings can go flying . Disassembly in a clean and small area could help in finding them if they were to go flying .

At the end of the lock cylinder there is a post that a small metal tube fits loosely over. (Indicated by the arrow), the tube is in place in the pic. The circles indicate where the 5 springs of the same size go (one spring post is out of view)

Before installing the anti-theft screw (refer to pic #1) Go ahead and test the lock mechanism.

More than likely this procedure is a one time occurrence for the life of the bike.
It's time to ride.
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2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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Last edited by bpe; 9-22-2019 at 10:24 AM.
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post #2 of 4 (permalink) Old 9-6-2019, 9:32 PM
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@bpe very nice job, this'll gain some legs when the forum maintenance project commences.

Your photo abilities have massively improved!
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“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #3 of 4 (permalink) Old 9-7-2019, 7:03 AM
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Awesome guide, thank you!

I do all my surgery in 9x9 baking tin. Catches anything that may go flying.
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post #4 of 4 (permalink) Old 9-7-2019, 10:49 AM
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Well done! Thanks for another worthwhile contribution. This may be better placed in the main knowledge section rather than the beginner section, so I've stickied it for now to keep it handy.
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Last edited by K-woppa; 9-7-2019 at 11:00 AM.
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