Gas cap key cover - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 4 (permalink) Old 08-11-2019, 02:48 PM Thread Starter
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Gas cap key cover

The little flap that swings out of the way of the key (key cover) has come off on my 2003 Volusia. I’d like to repair it.

Does anyone have a disasembly guide to the gas caps? Pretty sure I am also going to need a spring and small bolt but those can be bought or fabricated.

I found this post on later models. Wil try it on my 03

Last edited by Jb001; 08-11-2019 at 03:43 PM.
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post #2 of 4 (permalink) Old 08-11-2019, 05:42 PM
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I believe it will. Dont think they've changed it any.

I can head East or West, it doesn't matter as long as it's on 2 wheels.
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post #3 of 4 (permalink) Old 08-11-2019, 08:56 PM
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I drilled mine out, and put it all back together with a stainless steel rivet.
It took a bit of reshaping with a grinder.
It's not showroom quality, but it beat buying a new one, at least for now.

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post #4 of 4 (permalink) Old 08-12-2019, 07:09 PM Thread Starter
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I fixed mine. It was a bit different on my 2003 Volusia 800 than the other post.

After taking the gas cap off of the bike and turning it upside down there are two Phillips screws which I removed.

Once the two screws are out, the black plastic cover comes off revealing a metal plate which simply lifts up. Then the inner metal cylinder that contains the key cylinder lifts away from the gas cap.

You should now see a spring and the loose screw. Put the key cover into its hole from the outside of the cover. The spring goes over the shaft of the key cover and the screw mounts into the shaft.

I did not have lock-tite handy so used a drop of crazy glue in the screw hole..

Once reassembled, I suggest that you always rotate the key cover clockwise which will prevent the screw from undoing.
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