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Discussion Starter #1
Hey guys. I was going to check the fuel level in my 89 TRX350 when I couldn't get the gas cap off. It has the little plastic "lock/open" lever on top of it. It feels like one side isn't opening when I flip the little switch thing. I didn't want to just pry the cap off for fear I wouldn't get it back on. I tried to find a new cap online in case I just have to break this one to remove it, but they don't seem to be available.

Help? What's a fellow to do?
 

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Did you try pushing down hard on the fuel cap while turning the release knob...? You can spray some lube into the release mechanism around the release knob shaft to wet the two sliding pawls a bit.
 

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Hey Gray. Remove the knob mounting screw pull that black plastic knob from the stem and see if the knob is stripped out. If not you can spray some lube in the top of the cap–use some vice grips to turn the stem.

Usually the cap can be refreshed with the lube—my knob was cracked so I loaded it up with epoxy and it has held. Otherwise you can buy the minimum $40
 

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Discussion Starter #4
I did try pushing down hard on the cap. Still no joy :(

Cool! Thanks for the info. I'll try lubing it up and see if that makes it more amicable.
 

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Located two caps I'll PM you soon both right around $40 as goober stated.
 

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Discussion Starter #6
So after lubing the cap neither side will unlock. It's now worse than it was before. How do I get the cap off now? Drill it out? Beat it with a hammer?
 

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Discussion Starter #7
Well I got impatient. Pried it off with a crowbar, thoroughly broke the locking mechanism to ensure noone could lock it again, then held the cap down with a piece of random bracketry.

 

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Haha! You’ve definitely won ‘bodge of the month’ on this one :laugh:
 
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Well I got impatient. Pried it off with a crowbar, thoroughly broke the locking mechanism to ensure noone could lock it again, then held the cap down with a piece of random bracketry.


My cap is in the same situation. Loose but won’t release. I’ve been working it back and forth with a pair of channel locks. No joy. But prying it off seems to stress the tank itself and I don’t want to have to replace it too. How did you pry yours off?
 
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