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Hi, I think I've solved my filler cap problems as follows.
No matter how I pulled the cable - gently, quickly, pushing down on the cable behind the lever, etc. - there was always the chance that cap would not open. The catch always disengaged, but the spring by the hinge is too weak to always push out the flap. I haven't been able to remove the flap from its hinge and tweak the spring, so have opted for what seems a simpler and fairly infallible alternative.
I got some foam tubing that is used to lag 15mm water pipes. This comes in 1 metre lengths from DIY shops and is very cheap (e.g. 5 metres for £2 at Wickes). With a sharp knife I cut a short length of around 3 inches and then removed a segment of around 90 degrees, (see photo), which takes less than a minute. This then fits snugly on the inner fuel cap, which should be rotated until "horizontal". When the flap is closed the foam fits neatly into its curved inner surface, (see other photo). And the foam is squashed enough to always ping the flap open when you pull the lever.
The foam can be removed temporarily when at the pump, so doesn't get in the way of anything. If it gets lost or loses its flexibility, you've got enough left out from 5 metres of insulation to make about another 60 at around 3p each.
I hope this suggestion is of help to someone else.
Wilson, Brighton.
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