Fitting replacement fuel cap problem (GS1200)

[dudlow]

Hi

I may be missing the bleeding obvious but........

Having snapped off the opening part of my fuel cap (2004 GS1200)(clumsy refueling with tank bag on) I got a used replacement whole cap from Motoworks, minus the lock.

I have unscrewed the whole unit (removed the visible outer screws)removed it, undone the three cross head screws holding the lock mechanism at the back of the cap, removed the barrel from the old cap and inserted it in the replacement.
Replace the three screws, all back together now, but the bloody key won't open the cap/move

I have faffed around with it, but no go.

Presumably I may have unset the barrel settings during the swopover ? or have I missed something ?

Any help appreciated. Thanks.

 

[Rusty Bolts]

I have changed the barrel on mine before. I can't recall the finer details but I do remember that I left the key in the barrel. I only removed it when it the barrel was firmly inserted. Can't comment on the other stuff though.

 

[dudlow]

That may be the issue, thanks.
Anyone know how to get it working again ?

 

[nicholsonj2252]

You need to ensure that the last wafer (opposite end to where you insert key) has came all of the way through the filler cap and is pointed vertically upwards - see instructions below from service manual :

 

[Rusty Bolts]

That looks familiar

 

[dudlow]

You need to ensure that the last wafer (opposite end to where you insert key) has came all of the way through the filler cap and is pointed vertically upwards - see instructions below from service manual :

Thanks very much for that.
I did all that correctly, except I did not leave the key in, and pushed the barrel back in until it located as per the drawing.

Can anyone confirm that I now need to have it reprogrammed / reset ? And if so can I do it or is it a dealer job.

Thanks.

 

[nicholsonj2252]

Have you tried putting the key in then pushing the last tab in then trying to push the lock back out ? There is nothing to reprogramme as such its just without the key in the lock barrel wafers will likely have engaged in the internal locating slots in the fuel cap incorrectly

 

[Rusty Bolts]

I am going to ask the obvious but just in case, the barrel you are putting in is actually the one that your key fits i.e. the one that came out of your 'old' snapped filler cap?

 

[dudlow]

Give that man a coconut !

All now working fine. The pictures were helpful as well because the barrel was upside down.

Great forum, many thanks to everyone for your time taken in replying. A real help.

 

[dudlow]

I am going to ask the obvious but just in case, the barrel you are putting in is actually the one that your key fits i.e. the one that came out of your 'old' snapped filler cap?

My replacement cap came without a barrel, but good call anyway. Thanks.