🔧 K900 - Fuel Cap Replacement

Replacing the fuel cap on your K900 is a quick job that helps prevent fuel vapor leaks and can stop an EVAP-related check engine light caused by a weak seal. You’ll remove the old cap, move the tether (strap) if equipped, and confirm the new cap clicks and seals correctly.

Difficulty Level: Beginner | Estimated Time: 0.1-0.2 hours

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⚠️ Safety & Precautions

• ⚠️ Work with the engine off and away from sparks, cigarettes, or open flames.
• ⚠️ Do not top off the tank after the pump clicks off; it can damage the EVAP system.
• ⚠️ If you smell strong fuel fumes or see liquid fuel, stop and clean up before continuing.
• ⚠️ Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Safety glasses
• Clean shop towel
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (OEM-style, tethered if equipped) - Qty: 1

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📋 Before You Begin

• Park on level ground, shift to Park, and turn the engine off.
• Let any fuel vapors clear for a minute before opening the cap.
• Have a clean shop towel ready to wipe the filler neck sealing surface.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Use your hand to open the fuel door on the rear quarter panel.
• Use a flashlight to inspect the area for dirt or damage.

Step 2: Remove the old fuel cap

• Put on nitrile gloves and safety glasses.
• Turn the cap counterclockwise until it releases, then pull it straight off.
• If your cap is tethered, let it hang without twisting the strap.

Step 3: Inspect and clean the sealing surface

• Use a flashlight to look at the filler neck rim (the round metal/plastic ring where the cap seals).
• Wipe the rim with a clean shop towel.
• Tip: A dirty rim can cause leaks.

Step 4: Transfer the tether (if equipped)

• If the old cap has a tether strap and the new one does not, move the tether only if your replacement cap is designed to accept it.
• Use your hands to unclip the tether from the old cap and clip it to the new cap.
• Tip: Don’t force clips—plastic breaks easily.

Step 5: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise by hand.
• Tighten until you hear/feel at least 1–3 clicks (clicks mean the ratcheting mechanism is tight enough).
• Use a flashlight to confirm the cap sits flat and the tether isn’t pinched.

Step 6: Close the fuel door and final check

• Close the fuel door with your hand until it latches.
• Use a clean shop towel to wipe any fingerprints or fuel residue from the area.

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✅ After Repair

• Start the engine and verify there’s no fuel smell around the fuel door area.
• If you were replacing it due to a check engine light, it may take a few drive cycles for the light to turn off on its own.
• If the light stays on, the issue may be another EVAP leak (hose, purge valve, vent valve), not just the cap.

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💰 DIY vs Shop Cost

Shop Cost: $40-$120 (parts + labor)

DIY Cost: $15-$45 (parts only)

You Save: $25-$75 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.