gas cap swap

pcs

Registered
so a gen 2 cap will bolt up to a gen 3 but the plastic tank cover has a lip that’s in the way. if any of you care to use longer bolts and trim the lip you can get a green 2 cap to work. the plastic lip gets sandwiched between the cap base and the 4 bolt ring on top.

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so a gen 2 cap will bolt up to a gen 3 but the plastic tank cover has a lip that’s in the way. if any of you care to use longer bolts and trim the lip you can get a green 2 cap to work. the plastic lip gets sandwiched between the cap base and the 4 bolt ring on top.

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How do you remove the plastic cover on the tank? Tried to search but only sound stuff after its already off.
 
take the lock ring around the gas cap off. i open gas cap and stuffed a rag to reduce chance of dropping anything in there. then take the side panels under the handle bars, allen bolts and pushpins. then remove the hardware plus the 2 plastic push pins, hidden behind fairing on the actual tank cover. after that the gas tank cover has velcro on the sides and in the front by steering neck that is a pop pin. i grab the piece from the sides and lift fwd. i loosen the the upper side fairing bolts to allow my to move them enough access the side push pins on the tank. in the pic without the side fairing you can see the pushpin above the engine mount bolt and the black allen head bolt towards the front of tank. on the back u can see how the velcro attaches the side fairing.

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so a gen 2 cap will bolt up to a gen 3 but the plastic tank cover has a lip that’s in the way. if any of you care to use longer bolts and trim the lip you can get a green 2 cap to work. the plastic lip gets sandwiched between the cap base and the 4 bolt ring on top.

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Thanks @pcs, which part of the front tank cover did you trim, exactly? Trying to figure this out as well.
 
First time I see this thread and it’s pretty interesting. I assumed the gen3 gas cap was a 4 bolt design and my gen2 TWM cap would not work but, looks like the only thing with 4 bolts is that ring on top. I would love to use my keyless cap but, not sure how I feel about trimming anything on a new bike to make the cap fit.
 
Isn't it only 3 bolts that actually thread in, and the other 2 bolts are for looks/other models?
 
On the gen2, yes. Looks like the gen3 has that 4 bolt ring to sandwich the plastic cover between it and the actual gas gap. Gas cap
Itself looks like same 3 bolt design.

Gsxrs only use 3 bolts too.
I think all the same gas caps fit all Suzuki sport/sport touring bikes for at least 30 years now, lol
 
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