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hey noobie here. been riding for a few months now. bought a 95 intruder 800. The gas cap keeps rattling at high rpm's. I have the chrome custom cap as well. that fixed it for a week or so, but then the same rattling came back. anyone else experience this? any tips? thanks in advance, motherfreller
 

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Is it the entire cap rattling? Or do you have a cap with a little rotating tab that covers the key slot for locking the cap? That little tab can work loose and rattle, but you should be able to fix that by removing the inner part of the cap and tightening it up.
 

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This is a known problem with intruders. There are two different causes; internal and external.

Take your gas cap off, and shake it around by your ear. Do you hear anything? If not, then your gas cap is vibrating from side to side in the fuel filler hole. Find a piece of rubber and cut out a gasket to fit between the filler neck and the cap, and put it behind the factory one. Done.

If you hear anything rattle, then flip the cap over and remove the two philips head screws. Remove the black housing from the cap. Remove the brass washer/ spacer from the cap. You will see a brass housing with the lock cylinder in it. In this housing there are two small holes, one with a plug in it that has a very small hole in it. Use a sharp nail to pry off this plug, and remove and discard the small metal ball under the plug. This ball is supposed to keep fuel from dripping out the vent hole if you flip your bike over, and it is the source of the rattle. Put the cap back together without the ball, and no more rattle.
 

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Wow, Dr. Bob... that was a lot better than what I had :)
 

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No problem!
The VS has a different gas cap from the Volucia (C50)...we don't have that little flap, but I wish we did! Trust me fellow VS owners: squirt a little WD-40 in the keyway of your cap every now and then, or bad things can happen, especially if you ride in all weather or keep your bike outside...
 
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