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Thread: replacing a 2003 KGT fuel filler cap assembly ?

  1. #1
    Registered User jjciii's Avatar
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    Exclamation replacing a 2003 KGT fuel filler cap assembly ?

    I took apart the fuel filter (bottom of tank) to replace the hoses and did not mark the fuel 'filler' cap assembly so I do not know how to replace the 'filler' cap back after I was done with the bottom of the tank. The little drain hole on the 'filler' cap should face - ft, back, lt, or right side of the bike??

    I figure this may make a difference due to the little float thing connected to the filler cap and it's orientation inside of the tank. Sure are a lot of pipes and hoses connected to this cap assembly.

    Anybody with a kgt, please look inside of your gas cap and tell me which way to orientate the small drain hole.
    JC

  2. #2
    SURVIVOR akbeemer's Avatar
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    A look at an exploded view of the assembly on a parts fiche may provide the info you need.

    https://shop.maxbmw.com/fiche/partsfiche.aspx
    Kevin Huddy
    Silver City, Montana
    MOA# 24,790 Ambassador

  3. #3
    Registered User GTRider's Avatar
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    The “biscuit” should point to the front of the tank. That puts the drain hole for the capwell on the left side of the tank as you sit on the bike.

    Best,
    DeVern
    DGerber
    1983 R80ST 1984 R80 G/S-PD 2004 K1200GT w/Hannigan S/C 2010 K1300GT 2018 R1200GS
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  4. #4
    Debbie's Servant Lee's Avatar
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    Quote Originally Posted by GTRider View Post
    That puts the drain hole for the capwell on the left side of the tank as you sit on the bike.

    Best,
    DeVern
    That's how I remember it. Drain hole on the left and cap hinge at the back.
    Lee
    2016 R1200RS
    MOA # 30878
    Past BMW Bikes: 2011 K1300S, 2003 K1200RS, 1991 K75S, 1987 K75T, 1984 R100RT

  5. #5
    Registered User jjciii's Avatar
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    I sure appreciate the info. Dame BMW, why don't they give us an out of the tank fuel filter. Or if not, then not on the bottom of the tank! Same goes for the location of the air filter.
    But now I know and can finish putting it all back. But I will sure test for leaks before putting on all the plastic. Didn't change any of the gaskets, so hoping they all seal up fine.
    Not going with the paper air filter again however. Bought a Bikemaster filter and hoping it will last longer. Anyone hear about opening up the air box at all for any increase in power? That is something I did on my f800GSA. Three 1" holes covered by some Sealskin. If I was to open this air box, not sure where I would do it. Seems the gas tank covers closely to the box, not leaving any room for air even if you were to drill in some holes.

    Oh well, back to putting it together with your info.
    JC

  6. #6
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    '03 KGT fuel filler cap

    Quote Originally Posted by jjciii View Post
    I sure appreciate the info. Dame BMW, why don't they give us an out of the tank fuel filter. Or if not, then not on the bottom of the tank! Same goes for the location of the air filter.
    But now I know and can finish putting it all back. But I will sure test for leaks before putting on all the plastic. Didn't change any of the gaskets, so hoping they all seal up fine.
    Not going with the paper air filter again however. Bought a Bikemaster filter and hoping it will last longer. Anyone hear about opening up the air box at all for any increase in power? That is something I did on my f800GSA. Three 1" holes covered by some Sealskin. If I was to open this air box, not sure where I would do it. Seems the gas tank covers closely to the box, not leaving any room for air even if you were to drill in some holes.

    Oh well, back to putting it together with your info.
    ORRRRRR......you could try something like this.

    20210403_180346.jpg
    Just an old guy here. Killin' bugs at a rapid pace since '68. Desert dweller.
    Current force: '77 R100/7 ,'85 K100RS-Aug84, '85K100RS-Aug84, '85 K100RS-June85, '93K1100LTSE, '93 K75LTP, '98 R1100GS, '08K1200GT, (2)'72 CB 750s, '76 Honda CB500,

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