Gas Cap Won't Release

[Dimond]

Subject: R1200GS (2015) 'Keyless Gas Cap Won't Open'

My 'keyless' gas cap will not release so the cap will not open.  I removed the 2 torx bolts at the front of the gas cap and then removed the mechanical latch part held by the bolts so that I can refuel.  I am now trying to diagnose the problem and my first step is to troubleshoot the electrical release mechanism (without the mechanical latch part in place) to ascertain if the electrical system is allowing for a proper release.  However, I do not know how to 'troupleshoot' this mechanism.  Any suggestions are appreciated. Thanks.       

[AZgman]

I will ask the obvious; you do know that you can only open it for a short time after the ignition has been switched from on to off... correct?

[Cap]

.... or you need to pull the lever twice while your fob is within range.

[Bill_Walker]

Also, sometimes you need to press down on it to relieve the tension on the latch before the latch will release.

[Kerry in Mpls]

I had the opposite problem. The fuel lid on my '16 R12GSW would close securely, but you could lift the lever and it would release and open without the fob being in range. So it was usable, but I decided I wanted it to latch and lock as intended.

BMW wants $400+ for a new replacement "tank lid" part number 01 16 11 8 531 632, and the local dealership wanted an hour of labor to install it.

Too high, so I searched eBay and found a seller parting out wrecked bikes who offered the tank lid for $120.

I bought it and installed it in about an hour, nice to have it working properly.

 

[Dimond]

This post details the problem and the solution to my 'stuck' gas cap on my 2015R1200GS Keyless Ignition bike (75k miles). There are likely many potential causes, as others have noted, for having a 'stuck' gas cap - this post only details the one I encountered. The description below is my best guesstimate as to how the moving parts holding/releasing the gas cap interact.  The part that failed is BMW Part No 01-16-11-8-552-148, Tank Lid, MSRP $427 - the entire gas cap and filler tube is sold as an integral unit.  The price is what motivated my to try and 'fix it' rather than 'replace it'.  

 

Step 1 - Open Cap.

a) remove the 2 forward torx bolts at the front of the bike that keep the holding latch in place.

b) gently pry up the gas cap along with the holding latch -  remove the holding latch.

c) with the gas cap now open be sure to take some precautions to keep parts/dirt/tools from entering the fill tube.

 

Step 2 - Keyless Locking Mechanism Test.

a) there are two main moving parts that hold down (and release) the gas cap.

1. Horizontal moving rod - The horizontal rod moves horizontally when manually powered by hand movement when pulling up/down on gas cap lever.  Moving lever down keeps gas cap forward when bike is running and moving lever up moves horizontal rod out (towards rear of bike) to allow opening of gas cap when bike is turned off (and key fob is near bike).

2. Vertical moving rod - The vertical rod can move up and down via actuation (on/off) of a solenoid embedded within the 'tank lid' assembly. The horizontal rod has a vertical hole drilled thru it to allow the vertical rod to move up into the horizontal rod (gas cap closed) and down out-of the horizontal rod (gas cap open).  The vertical rod moves up via a solenoid (de-energized, ignition off)  return spring and down (for a short period with key fob nearby) via energized solenoid.  The foregoing mechanism enables a very small solenoid to create a very large resistance to a horizonal force (i.e., gas cap lever).  When you look down into the filler cap area you can see a very small diameter pin sticking up (when ignition is on) and then down (with ignition first turned off).  However, my solenoid was neither moving the vertical pin up or down - hence the problem - it was stuck!  

 

Step 3 - The Fix

I tried to push the pin down (ignition off) with a small screwdriver to no avail.  I sprayed electronics cleaner and dry air on the assembly to no avail.  The very small pin is connected underneath to a round plunger with a much larger body than the pin and accessible with a small diameter (20/1000 inch) punch down under horizontal rod.  Pushing very hard 'freed up' the vertical rod.  Once it was initially freed it easily moved up and down with the ignition on/off like it was supposed to.  

 

Lesson Learned: This expensive latching assembly is very ingenious - when it works - and a PITA when it does not.  I was out for 200 mile and it failed when I went to gas up.  I was able to get home with a few miles left in the tank - but I will be packing a Torx driver with me on future rides as it is not much of a problem to 'tank up' when you have this tool in your possession!  Thanks to those of you that offered opinions and suggestions!

[ScottT]

Hopefully you have an extended warranty if it fails completely. Mine has already failed on my 1250RT. When it fails they replace the entire assembly. Parts + labor is over $600 if you don't have warranty coverage. Horrible feature.

[TestPilot]

Why is this starting to sound a bit like the hexhead fuel strip problem - poor engineering with no real solution except $$$.

 

[alegerlotz]

5 hours ago, TestPilot said:

Why is this starting to sound a bit like the hexhead fuel strip problem - poor engineering with no real solution except $$$.

 

Its not nearly as pervasive as the fuel strip problem for one thing...

[AndyS]

12 hours ago, alegerlotz said:

Its not nearly as pervasive as the fuel strip problem for one thing...

 

alegerlotz, you are dead right.

[jcwvfr]

Good Afternoon, now I have this problem on my 2018 R1200RT With 24,xxx miles on it. I couldn’t get the cap open at the gas station today no mattered what I did, I knew I had enough gas to get home so I cut short my joy ride. You can take the front two bolts off the ring and the lid will pop right open. Dealer told me over the phone... yeah sometimes they break?!?! Told me I can bring it in and they will take a look at it. I cleaned it with carb cleaner, toothbrush and compressed air and it work fine..... came back out 20 minutes later.... nope won’t open.

[Motorhead1977]

On 10/22/2019 at 6:07 PM, TestPilot said:

"...... poor engineering with no real solution except $$$."

Since purchasing my '18 RT new in February 2018 I've come to the realization that the above seems to be the BMW mantra. That combined with "We did it this way because it's more difficult, aren't you impressed with us?". My last BMW was a R65 LS many long times ago. Have had many different bikes in between. Yes I know everything is high tech now but IMHO BMW rival HD in the taking $$$ out of your wallet and expecting you to be glad for the opportunity.

Thanks for the tech info on the interim remedy. I always have a set of torx bits in my bike.

 

[92Merc]

20 hours ago, jcwvfr said:

Good Afternoon, now I have this problem on my 2018 R1200RT With 24,xxx miles on it. I couldn’t get the cap open at the gas station today no mattered what I did, I knew I had enough gas to get home so I cut short my joy ride. You can take the front two bolts off the ring and the lid will pop right open. Dealer told me over the phone... yeah sometimes they break?!?! Told me I can bring it in and they will take a look at it. I cleaned it with carb cleaner, toothbrush and compressed air and it work fine..... came back out 20 minutes later.... nope won’t open.

You may have cleaned it out well, but you need to add some lube.  Something like silicone lube.  With all that cleaning, you just have dry parts with lots of friction.

[Rougarou]

Ya, I haven't searched this, but I'd really like to convert my GSA back to keyed ignition and tank cap  Not that I've had any issues, but I use various jackets and have gotten to the bike only to have to go back into my building to retrieve the fob from the morning jacket.  Never had that issue on any of my keyed bikes.

[Bernie]

6 hours ago, Rougarou said:

Ya, I haven't searched this, but I'd really like to convert my GSA back to keyed ignition and tank cap  Not that I've had any issues, but I use various jackets and have gotten to the bike only to have to go back into my building to retrieve the fob from the morning jacket.  Never had that issue on any of my keyed bikes.

Curious, where did you leave the key for your other bikes?

[Rougarou]

1 hour ago, Bernie said:

Curious, where did you leave the key for your other bikes?

 

Since it was the ignition, I'd pull it and put in my pocket.  Since this little dongle goes nowhere, I don't' much like it.  If I put it in a jacket pocket, then use a different jacket, I gotta remember which of the five-six pieces of gear I used last.  I don't like to carry things in my pants pockets much either,....a carryover from active duty. 

 

I've reduced my wallet, to nearly nothing, six essential cards/IDs, keeps my pockets nearly empty/flat.

 

All keys for my vehicles have only the keys/fobs for "that" vehicle.  No extras, no house keys, no trailer lock keys, no work keys, this keeps things to a minimum. 

[Bernie]

I only have one riding suit. I have it hanging on a S-type carabiner and just clip it on my belt loop, before doing my RoadCrafter Suit.

My problem witch the keys was that I would forget to get them out of my pants before getting my Stitch zipped up.

I guess they call this a new world problem? 

[bendbill]

6 hours ago, Rougarou said:

 

Since it was the ignition, I'd pull it and put in my pocket.  Since this little dongle goes nowhere, I don't' much like it.  If I put it in a jacket pocket, then use a different jacket, I gotta remember which of the five-six pieces of gear I used last.  I don't like to carry things in my pants pockets much either,....a carryover from active duty. 

 

I've reduced my wallet, to nearly nothing, six essential cards/IDs, keeps my pockets nearly empty/flat.

 

All keys for my vehicles have only the keys/fobs for "that" vehicle.  No extras, no house keys, no trailer lock keys, no work keys, this keeps things to a minimum. 

 

 ^^^   another vote for a return to basics. I don't like the key fob and prefer a slim wallet.   I'd give up keyless ride and tire pressure monitor--needless complexity.  And in 2 years of my RT, the radio has never been turned on, and it never will.

[Rougarou]

4 hours ago, BendBill said:

 

 ^^^   another vote for a return to basics. I don't like the key fob and prefer a slim wallet.   I'd give up keyless ride and tire pressure monitor--needless complexity.  And in 2 years of my RT, the radio has never been turned on, and it never will.

Ya, the only things I don't mind in my pockets are my benchmade mini auto presidio II or my kimber micro9,.....of course, not in the same pocket

[TEWKS]

37 minutes ago, Rougarou said:

of course, not in the same pocket

I’m sure you’re aware more than most, you don’t want to accidentally bring a knife to a gunfight! 

[Hosstage]

Had my bike had not come with the security system already installed (an option in 2001), I would not have ordered it. An electronic locking gas cap just seems needlessly complex to me. While mostly convenient, certainly frustrating when not working properly.

But then, I'm just a Luddite from the old days!

I miss wing windows...

[Rougarou]

1 hour ago, TEWKS said:

I’m sure you’re aware more than most, you don’t want to accidentally bring a knife to a gunfight! 

 

Dat's why I got two pockets on the right side of me body

[wbw6cos]

8 hours ago, TEWKS said:

I’m sure you’re aware more than most, you don’t want to accidentally bring a knife to a gunfight! 

 

 

From what I understand, Marines bring both!!  

[TEWKS]

13 minutes ago, wbw6cos said:

 

 

From what I understand, Marines bring both!!  

I bet they do! 

[Rougarou]

this is going way off topic, but had to say it.  My wife asked one time if I had my knife with me, my reply,.........I have my pants on don't I?

[Hank in WV]

As I recall, they are trousers...

[Rougarou]

35 minutes ago, Hank in WV said:

As I recall, they are trousers...

 

Let me wean a little terminology away from the active duty days,.......also, I no longer wear blouses.

[Hank in WV]

And don't forget cover... Semper Fi  

[Rougarou]

10 minutes ago, Hank in WV said:

And don't forget cover... Semper Fi  

 

Ya, it's occasionally still a cover, yut-yut

[Adventure Tyler]

Similar problems here both opening and closing R1250GSA Keyless gas cap. I don't think its an issue with the keyless system though.  Its the mechanical latch.  I finally removed the separate tank ring section that covers the keyless mechanism.  I then filed down the two " tabs" on the lip that holds the mechanical latch on the gas gap when it is in the closed position.  I almost completely removed the tabs and then even filed the underside down so the fit wasn't so tight when the gas cap is closed.  Make sure to file the tabs at an angle to maintain a somewhat sharp edge and then file the bottom flat side second to also help keep the "sharp" edge.

  

COMPLETELY fixed all problems.   I think that separate tank ring section moves too close to the gas cap when tightened and doesn't provide enough clearance to open.  I have read that people have better luck when they don't tighten down the ring all the way so it makes sense and this is a better solution.  Poor design and tolerance issues on BMWs part!

 

Happy Trails!

[JamesW]

You know the only reason I read this wethead forum is for entertainment because I wouldn't own a new BMW if you gave me one.  A keyless gas tank cap??  How lame is that I ask and then I got to the part about what a dealer would charge for a new installed keyless gas cap, ohhhh man!  Just knock me down and call me stupid, seriously.  Well, sort of.  Then I was in the local Napa auto parts store buying some oil the other day for my trusty '93 R1100RSL you know the low tech keyed gas cap bike,  and one of the store employees told me about BMW cars having no oil level dip sticks and we all had a good laugh over that one.  

 

Honestly, I just can't see why anyone would buy one of these high tech wonders.  For the life of me I just can't.  I mean I can just imagine what my reaction would be if I was out somewhere in the middle of nowhere at a podunk gas station with my high tech wonder and I couldn't get the gas tank open.  I swear I would take a jagged rock to the POS.

[MikeB60]

I honestly can't understand why anyone would NOT buy one of these high tech wonders...

[wbw6cos]

Without high tech, there might not be a forum to comment about high tech wonder on bikes.   

 

I never thought I would like keyless ride and originally did not want it, but it grew on me.

 

I do like power door locks (with FOB) on my '06 car.  I still see people sometimes using a key to unlock the car door and wonder why power door locks is not standard equipment.  

 

Do kids these days understand the meaning of roll the window down?

[Skywagon]

I like tech....it's where I made my living also.  So here is a couple of gee whiz's our grandparents would not have understood.  My cars wipers...come on when its raining, turn off when it's not...go slow or fast depending on the rain. I haven't touched the light switch on a car in over 15 years.  I put it on cruise...if I get too close it slows down, if it opens up it speeds up, if something pulls out in front of me it hits the brakes and shakes the seat.  It has an auto drive.  I get on the freeway for long trips and I put my hands in my lap as it knows the way.  If I am not sure where something is I punch a button and the nice lady ask what I want.  I tell her I want dinner reservations at X restaurant for 2 in X city at 6pm....and oh by the way can you put that in my gps...done.  I see tire pressure of all tires.  Folks in the back can watch TV or video....yep TV same as home cable. I can start it, lock it, cool it, heat it, all from the comfort of my couch before I go out.

 

Well...my car is nothing special these days.  It has more things as most cars do these days.  Oh yeah it doesn't even have a gas cap and it's not an electric.  Knock on wood after driving this vehicle for 4 years now not a single thing has broken.

 

My first car......had a heater that worked most of the time.  It started most of the time if you didn't flood it.  That was pretty much it.

 

So....keep brining me that tech.

[JamesW]

"So....keep on bringing me that tech."

 

You are certainly welcome to my share.   Out of curiosity, what is the make and model of this hi-tech chariot you cruise the highways and byways in?

 

[Motorhead1977]

I absolutely love the tech...... until something malfunctions and I need a bevy of NASA engineers to correct it. Then I long for the days of my 67 Chevy SS or my 71 FIAT 124 Spider. They were pretty simple so there were a limited number of things that could malfunction and they could usually be corrected with very simple tools and procedures. That said I still love the tech because I don't have to perform maintenance like changing spark plugs every 3,000 - 5,000 miles and can count on getting at least 200,000 miles from my vehicles.  On the whole the tech makes my life much easier.

[JamesW]

Well Skywagon, really, what is this car you own??  I just got to know.

 

[Skywagon]

James... wait for it...as I said just a basic car these days. 2017 Tahoe LTZ 5.3 v8. Gets about 26 MPG on the Hwy. oh yeah it can heat and cool your tush   Memory seats. No key needed to open or lock. Has a secret compartment to lock my firearm in requiring a code to open.  At least 8 USB ports. Can open tail with waiving my foot  That level of tech is pretty standard now. This is my 3rd Tahoe in a row. Wouldn’t drive anything else. Tows my fishing boat great but mileage drops to 16

[JamesW]

 

2 minutes ago, Skywagon said:

James... wait for it...as I said just a basic car these days. 2017 Tahoe LTZ 5.3 v8. Gets about 26 MPG on the Hwy. oh yeah it can heat and cool your tush   That level of tech is pretty standard now. This is my 3rd Tahoe in a row. Wouldn’t drive anything else. Tows my fishing boat great but mileage drops to 16

 

I'm amazed, a Chevy of all things??  Well, that leaves me out me being a Ford guy 100%. ( lots of lol..lol..)  I absolutely lust over a '39 Mercury truth is.

 

Thanks for the reply as I was really curious.  

[Janky59]

12 hours ago, Skywagon said:

Oh yeah it doesn't even have a gas cap and it's not an electric.

I think it was this that had people scratching their heads.
I guess you mean it doesn’t have a screw on cap, the access door seals off the filler neck area, my ‘13 Flex has that setup.

[wbw6cos]

What about a spare tire?   Quite a few of the new automobiles that I have rented do not have the donut spare, just an 1-800 # to call; I was thinking manufacturers were moving in that direction.  Could be a rental thing.  Dunno.   I am also not sure about the large vehicles such as pickup trucks, SUV's, and such as the like.

[JamesW]

I think all this infatuation with these techno gizmos is a sad commentary on American society today.  

 

For the record I am also a retired telecom specialist.  That said I retired in '95 and am definitely closing in on the big 8 zero so I was educated in an analog world which no doubt influences my thinking on today's wondrous world of gadgetry.  

[Skywagon]

WBW. Full size spare

 

James.. Let’s go install some D4 Channel Banks with CSU’s into some Stat Muxes. Will bring back memories. Let’s give the 56k per channel and one 8k channel for signaling.. or we could just put in a router that would be the equivalent with gigabit which would be 608 times faster in a box the size of my palm... all wireless of course 

 

James The principals of what you and I learned many decades ago still apply to most things today. You would be right back in the saddle in about 2 days

[JamesW]

Hi David,  Don't make me laugh (cry) there would be little chance of that.  We would have to do something about my short term memory issue and then we would have to see what we could do about my overall energy level.  Even the 14 year old siamese cat has dementia.  You ever see a cat with dementia?  Not pretty nope... not pretty.  

 

Here I sit trying to decide which bike to sell first.  Looks like it will be the FJR for obvious reasons.  Good luck to me after Yamaha's world wide recall on the 2016 - 2020 6 speed FJRs.  Put a big black mark on the FJR no doubt including gen2 bikes like my 5 speed '10 FJR.

If I had one of the recalled bikes I would be afraid to ride it after having the recall work done.  The engine has to be removed from the bike and the entire transmission replaced because of a weak second gear that could fail causing massive engine damage and if the drive train were to lock up while in motion the results could well be catastrophic for the bike and rider.  Several events have occurred without rider injury as far as we know.  Just bad karma all the way around.  One big problem is finding a Yamaha dealer capable of major surgery on the FJR.  Our local dealer has never even seen one and he's not alone.

 

I was disappointed when BMW integrated the transmission/engine.

 

Well, time for happy hour.

[Hosstage]

At a family party during the winter months, I mentioned going out to start the car and let it warm up. Someone mentioned using the remote starter. I held up the key (no fob for the '99 Camry!) and said I am the remote starter. Manual tranny too, a foreign concept to most. Kind of miss that car.