gas-tank-filler-cap-venting–677

Dear BMW BUTLER & SMITH, INC. EAST WALNUT STREET & HUDSON AVENUE NORWOOD, NEW JERSEY 07648 201 • 767•1223 June 16, 1977 WEST 135 EAST STANLEY STREET COMPTON, CALIFORNIA 90224 213. 638-8508 Re: Gas Tank Filler Cap Venting R60/7 From VIN 6 100 001 to 6 100 407 R75/7 From VIN 6 120 001 to 6 121 470 Rl00/7 From VIN 6 140 001 to 6 142 340 RlOOS From VIN 6 160 001 to 6 161 323 RlOORS From VIN 6 180 001 to 6 181 262 Dealer: This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. BMW Motorrad GmbH has determined that a defect relating to motor vehicle safety exists in certain 1977 model gas tank filler caps, manufactured up to June 1977. The vehicles affected were delivered with filler caps which have ( pressure relief valves incorporated. These valves could allow pressure build-up in the gas tank, which overrides the closing pressure of the float valve in the carburetor causing overflooding. This gas overflow could result in a fire hazard. A modification of the gas cap is therefore required to prevent any pressure build-up in the gas tank. The procedure for drilling a vent hole in the present /7 gas cap is as follows. Please study the enclosed drawing first. 1. Turning the gas cap upside down, the four hol8s (a) will be exposed and facing upward. 2. In order to find correct dead center, scribe two lines through a pair of corresponding holes. Slightly center punch the point where the two lines meet. 3. Using the chuck of the drill as a depth gauge, secure a 1mm (1/32″) drill bit in its correct exposed length, so the free length will not exceed 22mm d8pth maximum. 4. Coat the drill flutes with a thick gre~se. EXCLUSIVE U.S. IMPORTERS OF BMW MOTORCYCLES ( – 2 – 5. Upon completion of Step #4, drill a 1mm (1/32″) hole at the exact center which you located in Step #2, or as indicated (x) in the drawing. CAUTION: Drill the sheet metal part first. You will then feel approximately 18mm of air space, then, hit the nylon valve casing (b), which is very soft, and then approximatel: at 21 to 22mm, you will feel that the drill will break through this first casing. Stop drilling immediately. In studying the enclosed drawing, you will see that the air gap (c) between the valve casing and the lock cylinder is very, very small. 6. WARNING: In order to prevent the gas cap from being destroyed do not drill into the lock cylinder (d) or beyond the breakthrough point of the drill, through the valve casing. 7. Thoroughly clean the cap to ensure all drilling chips have been removed and then blow dry with compressed air. 8. The gas cap modification has been completed and the cap can be reinstalled. All customers have been notified of this recall campaign in accordance with the National Traffic and Motor Vehicle Safety Act. All 1977 models already sold retail have priority. This modification must be made on all existing 1977 motorcycles which have been sold retail, or are on your showroom floor, in your warehouse, or in transit to you. With this letter, we are sending you perforated IBM cards, identifyin~ those bikes which have already been sold retail, and those which are in your stock. Any new purchases will have these cards attached to the invoices. In order to confirm fulfillment of the work outlined in this notification, please sign and return one perforated IBM card per modified vehicle, as identified by the vehicles’ identification number. Upon receipt of each card, signed by you and the customer, we will issue a credit of: All Models ……………… 3.36 dollars All completed cards are to be directed to the attention of the under·· signed, at the Norwood, New Jersey office. Under no circumstances shall new 1977 model BMW Motorcycles be delivered to any customer without the foregoing modification. Enc. Perforated IBM cards Filler Cap Drawing Very truly yours, BU1’LER & SMITH , INC. Service Manaqer /7 MODE-LF ILLERC AP BOTTOVMIE W : d I I C I ~ CROSS SECTION Attachment to Dealer Notification June 16, 1977 (‘ (