Sportbike gas cap mod / How To (9 PICS) - Road Star Warrior Forum : Yamaha Star Warrior Forums

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Old 03-30-2006, 10:35 AM   #1 (permalink)
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Default Sportbike gas cap mod / How To (9 PICS)

I wanted a gas cap that had a more aggressive look to it and one that was mostly black with some chrome. I decided on the ProTek keyless gas cap designed for a 2002 Yamaha R1. This is a step by step on the minor modifications to install it on a Warrior.

1. This is the base in stock form and it comes with stainless steel hardware. For the 2002 R1 it mounts with this 3 bolt pattern.

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2. You can see the two additional button heads that I removed to make it line up with the mountings on the Warrior gas tank. I then drilled these two holes out to 7/32 on the drill press.

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3. On the bottom side there are 3 stand off's for the R1 stock mounts. I removed the 1 at the 12 o'clock position with a dremel.

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4. I removed all the stainless hardware.

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5. I replaced all the stainless hardware with chrome hardware from "Air Fasteners". You can see the 4 bolts that will now be used to mount this to the Warrior's gas tank. These new bolt positions line up perfectly with the gas cap mountings on the Warrior. The gas fill opening and rubber gasket also line up perfectly.

HARDWARE:

http://www.afchromebolts.com/catalog_metric_allen.html

All button head bolts are (5mm x .[img]/emoticons/emotion-11.gif[/img]

1. Short bolts are all 8mm long.
2. Long bolts(for mounting) are 30mm long. (orded 2 extra)

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6. I used an extra 30mm button head bolt to fill that 12 o'clock hole. I used a lock nut and dremeled off the excess length. There is not much room for any extra here. I used aluminum spacers that I milled down to just over 5/16 to act as new stand off's under the 2 new mounting holes that I drilled out next to the 12 o'clock position. I also painted the newly exposed raw aluminum with semi-gloss black paint just in case some rain got to it.

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7. This is the final look with the 4 mounting positions, and the gas cap threaded in place.

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8. Final look installed on Warrior gas tank.

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The actual gas cap that threads in place has very fine threads on it so you have to be careful not to cross thread it. It also has a rubber O ring to seal it. This gas cap does not need to be very tight at all, if you over tighten it will damage the O ring easily.
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Old 03-30-2006, 10:58 AM   #2 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

awsome job!!
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Old 03-30-2006, 11:24 AM   #3 (permalink)
 
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Way cool
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Old 03-30-2006, 11:29 AM   #4 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Looks great. I just may have to do this one myself, too.
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Old 03-30-2006, 11:29 AM   #5 (permalink)
 
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Very nice, again you got skills!

Andrew
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Old 03-30-2006, 11:32 AM   #6 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Frickin' slick. I love it!!
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Old 03-30-2006, 12:13 PM   #7 (permalink)
 
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Very nice. Aggressive look. I like it.
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Old 03-30-2006, 12:36 PM   #8 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Looks good, kinda looks like my stocker that I painted and polished the bolts...only about a mil times better! LOL!

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Old 03-30-2006, 02:32 PM   #9 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Great look and great attention to detail. My hat is off to you!
Andy
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Old 03-30-2006, 06:34 PM   #10 (permalink)
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Default Re: Sportbike gas cap mod / How To (9 PICS)

Nice mod, looks cool.
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