stuck gas cap

[michael]

A few questions about stuck gas caps. If I have to drill the lock out what size bit should I use? How deep should I drill. Can the cap be used after it is drilled? This process is scary to me and I am note sure what to do. Thanks for any advice.

[Motorhead]

had the same problem

don't drill the key area the piece that catches the thread plug failed so what you want to do is drill hole and tap 6m the top to capture plug area

LIFT lever drill right next to the higher part center of lever recess

I used under the lifting lever to turn it to place my tap hole so when I FINISHED I could use my cap again cut off the excess screw smooth it out paint or leave it

[Jean]

If it's stuck ON the tank, try to remove it before you do any work!!
Put some kind of stick or rod thru the bail (lever?) and pull UP hard while rotating the cap to undo it.
It will probably come off.
This has worked for me with the '78 R100s. I was able to find an old cap and salvage the insides and rebuild mine so the key is the same and it does work OK now.
They (BMW) say you cannot do this, but you can; you just have to be careful taking the cap apart so it can be put back together.