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:???:At about 5400 miles I began to notice a rattle that seemed to be coming from the valves. I had the valves serviced and also had all the chassis bolts checked. When I got my bike back I still had this rattling sound. I began searching for the source and noticed while going down the road I could put my hand on the gas cap and apply slight pressure and the rattle stopped. I added an o-ring on top of the factory seal and the rattle stopped, after a 285 mile ride, the rattle returned. I checked the screws that hold the cap together, I tightened them. Has anyone else had this problem? Is there an aftermarket replacement cap? Is there a remedy without purchasing a new cap? Any help would be great.
 

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I added an o-ring on top of the factory seal and the rattle stopped,
Before you get too carried away, consider the possiblility that your "fix" didn't actually do anything and was just a coincidence.

The rattle may be coming from something ELSE on or under the tank.....or you may be moving your body enough when pressing on the cap to change your position on the seat.

Try pressing on the tank but NOT on the cap itself.
 

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As soon as I saw the title I KNEW you had a VS800- the Intruder 800/S50 is notorious for gas cap rattles. No one makes a replacement cap for it either.

The best way to get rid of the rattle is to take the cap apart by removing those two scres on the bottom side. Take it apart, remove the large washer looking thing, and you will find a small brass plug with a tiny hole in it. This is the vent. Pry the cap off with a nail or small drill bit. Under the cap you will find a small ball. The idea is that if you dump your bike the ball will block the vent and prevent gas from dripping out. This ball is the source of your rattle. I figure if I drop my bike a couple drops of gas out the vent is the least of my worries. Toss the ball in the trash, put the cap back together, and no more rattle. If the cap eventually starts to make noise again, cut a new rubber gasket to replace the round one, but the original one should last for a long time.
 

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Thank you once again Dr. Bob. That rattle was driving me insane. You asked me in a previous thread, "why are you worried about the valves so soon?". That rattle was the problem the whole time, not the valves. Thanks again.
 

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As soon as I saw the title I KNEW you had a VS800- the Intruder 800/S50 is notorious for gas cap rattles. No one makes a replacement cap for it either.

The best way to get rid of the rattle is to take the cap apart by removing those two scres on the bottom side. Take it apart, remove the large washer looking thing, and you will find a small brass plug with a tiny hole in it. This is the vent. Pry the cap off with a nail or small drill bit. Under the cap you will find a small ball. The idea is that if you dump your bike the ball will block the vent and prevent gas from dripping out. This ball is the source of your rattle. I figure if I drop my bike a couple drops of gas out the vent is the least of my worries. Toss the ball in the trash, put the cap back together, and no more rattle. If the cap eventually starts to make noise again, cut a new rubber gasket to replace the round one, but the original one should last for a long time.
When it comes to answers to questions on the S50 DR BOB RULES
 

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Gas Cap doesn't Rattle no more.

This is my first post to the motorcycle Journal Forum so a big hello to everyone, I've really enjoyed the Forum so far.
Hey Dr. Bob, I want to thank you for sharing the info. on the rattling gas cap, it works on the Intruder 1400 as well. In the last two days I've found great information for fixing things on my new bike (1999) that no service dept. or anyone else seemed to have a clue about. Duane Ausherman (I'll call him the Key Master) explained beautifully with pics how to remove an old steering lock (didn't get a key with it) and replace it, about a 10 minute job.
It's guys like you and Duane that make the internet one very valuable tool.
Thanks again!!!!
PS: When I bought the bike about 3 weeks ago the guy said the one thing that was driving him crazy about the bike was the rattling gas cap, he had foam and rubber, all kinds of stuff glued underneath it to stop the rattle. Should have talked to Dr. Bob.
Sincerely,
Ron Smith
 

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Gas Cap Rattle

Hi Everyone, I to also have a 2002 Intruder 1400 which had a rattle. For me the quick and easy fix was to just place Velcro on the under side of the cap. ( on the longer end) It just keeps enough pressure on it to keep it from rattling.:bluethum:
 

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About the same miles my cap did the same thing. It wasn't the tank, just the cap. I fixed it by inserting a rubber shim under the long side of the cap causing the cap to be slightly tipped. 11,000 miles later it still works. Good luck.
 

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WOW...That was the rattle I had as well. Now Good Sirs, what pray tell is the whine from the left side by the drivers feet that sounds like a belt whine from 50 to 60 mph in 4th or 5th gear. And thanks so much for the rattle repair. Daddi0
 

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I went to local advanced auto parts store and found a thermostat gasket for a Ford v6 244 engine 1986-94 part number 35404 and then took apart gas cap and took out gasket and the frame it kinda sits on and put thermos. gasket around it like it was a thermostat and it fixed the leaking and the rattle for only 4.85$
 
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