TOPIC:

Want to remove my fuel gas cap from my 77' KZ1000A gas tank and looks like a roll pin of some sort that has to be tapped out ?

How do you move this pin to remove the gas cap ? I'm going to get the gas tank powder coated.

If in fact it is a roll pin that has to be removed, can you re-use this pin ?

It is a pin (see part marked # 2 at www.powersportswarehouse.com/p/Kawasaki#...00-A1-1977/070080E-7).

You should be able to drive it out using a drive pin punch (see www.google.com/search?q=drive+pin+punch&...8x4KHd-9BxgQ_AUIBygC for images).

If you do this be sure to use many, many small tap. tap. taps. rather than one or two King Kong bashes, otherwise you may bend the mount on the fuel tank that the pin goes through. It may even be a good idea to give the pin a little squirt of lubricant first so it doesn't bind. Ed

If the old pin gets damaged during removal, oe if it is rusty, any decent hardware store should stock one that will work.

Does anyone know what size this hinge pin is ? I'll be driving by ACE on the way home tomorrow and could drop in to see if they have something that will match.

Drive the old one out and match it up. I used a 16d nail with the end flattened as a punch. I now have a real one but the nail worked fine.
Steve

I'm soaking it in Kroil oil tonight. Will try to tap it out in a couple of days.

The pin is not the problem, it's the bracket the pin goes through. If you try to hammer on the pin, the whole bracket will bend before the pin budges .001". Advice is to somehow try to hold the bracket with a backing such as a piece of wood ect. You will ruin the tank otherwise. Pin can be reused forever, it's the removal and reinstall that is crucial to hold a backing to the bracket to avoid bending and ruining it.

Try not to make any sparks in the process or it could get rather eventful.

Removed pin this morning, Easy Peasy Just light taps a few times with a small upholstery hammer which exposed the other half of the pin on the opposite side. Pulled out easily with my fingers.

Bracket looks fine as with the pin. Got to love that Kroil oil

Thanks for the advice