Gas cap disassembly

[Supercoyote]

Hey, anyone know the secret to disassembling an XS360 gas cap? I've gotten to the point I see no way of removing the "puck" and have no more screws to take out

 

[BBS360]

I used a Dremel tool to shave the heads off the three studs. It falls right apart after that.
Make note of the order the pieces come off, as well as the orientation of the vent holes that go through a few of the pieces.
If the tank can't breathe through the vent hole the engine will starve.

Rivets worked to reassemble after cleaning, lubing, and installing a new seal.
Use the shortest rivets that'll work. Mine seems to catch slightly sometimes when closing the cap.

 

[xschris]

The xs400 caps have three screws holding the "puck" down.

 

[Supercoyote]

Ah ok .so then shaving the rivets off is the only way. Thanks folks

 

[Supercoyote]

I used a Dremel tool to shave the heads off the three studs. It falls right apart after that.
Make note of the order the pieces come off, as well as the orientation of the vent holes that go through a few of the pieces.
If the tank can't breathe through the vent hole the engine will starve.

Rivets worked to reassemble after cleaning, lubing, and installing a new seal.
Use the shortest rivets that'll work. Mine seems to catch slightly sometimes when closing the cap.
View attachment 31539 View attachment 31540

I'm trying to find a suitable seal online, did you have any luck from a dealership? Or cross referencing off another bike? I'm not coming up with anything

 

[BBS360]

The 20-0036 seal was a perfect fit:
http://www.xs650direct.com/products-34.html

If you're looking for more from them browse on MikesXS, because it lists other compatible bikes like your 360, then buy the same part # on xs650direct.
Usually works out.