I'm finding the worst problem I have fueling up isn't any of the issues I've seen on these forums - I get a full tank every time, the sensor seems to be fine, don't have any issues with pumps cutting off too early, etc.

But every time I pop that fuel door, and worse, every time I close it, it feels like a thirty cent piece of junk - I am cringing in fear at every moment I touch it, thinking I will snap it off.

As a fan of the older Z'x and ZX's, I had a thought to remove the fuel door entirely, and add on a locking cap which is similar to the old design. Or possibly a fill-though cap as I had on one of my Z's, where I locked it on and only took it off about once a year for maintenance and to make sure it wasn't rusting or anything of the sort.

Failing that, I'd like something a bit more solid and smoother - the hinges on this fuel door don't open and close smoothly, but seem to twist slightly and hesitate at about an inch open - I can see no damage to the hinge mechanism, I'm thinking it is just the way it is designed and the poor quality of materials.

Any ideas on either solution?

 

get a "chrome" stick on cover from discount auto parts, that will give you the stability you desire. lulz

 

Should be smooth, but the whole door is quite flexible.

Try unscrewing and aligning, i actually fitted several washers between the bracket and the hinge in order to make the door more flush with the body.