Fuel cap stuck! - Page 3 - KawiForums - Kawasaki Motorcycle Forums
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post #21 of 25 (permalink) Old 11-26-2012, 02:16 PM
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pour a lil gas on the key hole and bang on it as u kep go from lock to unlock position..i just had this issue for the past 2 days and i got it open then took it off and lube it up
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post #22 of 25 (permalink) Old 12-23-2012, 04:33 PM
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Mine seized...got it free and lubed it. A week later it seized. Got it free and disassembled it, completely cleaned it out, and lubed it. Two weeks later it seized. Got it freed up, disassembled it and cleaned it all up a 2nd time and lubed it. 3 weeks later it seized and left me stranded.

Moral of the story: Throw it away and buy an aftermarket or non-locking cap. I think the ethanol in the fuel corrodes everything in there...my locking "fingers" were all pitted up.

Currently my daily beater- 30k+ and counting the miles
07 ZX6R, lime green. Bafflectomy performed on stock muffler, disabled exhaust valve, Jumper mod, K&N air filter, PC3 with generic Euro-spec map, NGK Iridium plugs, Motul 300V & K&N oil filter, Healtech X-TRE, Drive Systems Superlite X2 steel sprockets -1/+3, Green EK chain, EBC Sintered HH pads front and rear, Dunlop Sportmax Q2's.

Last edited by OrLackThereof; 12-23-2012 at 04:35 PM.
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post #23 of 25 (permalink) Old 12-26-2012, 07:51 PM
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Clean it out best you can and lube up the hinges. When you put your key in, press down on the cap itself. That will relieve a little bit of pressure so you don't break your key trying to twist.
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post #24 of 25 (permalink) Old 12-26-2012, 08:56 PM
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Rust cure 3000 worked wonders on mine.

Spray it in the key hole then work the key around. Spray in some more and jiggle the key while pressing on the cap. Once you get it open spray some on the locking tabs and turn the key back and forth to work it into place. I did this two years ago and the gas cap still works fine.

Of course I'm generalizing from a single example here, but everyone does that. At least I do.


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post #25 of 25 (permalink) Old 12-26-2012, 10:30 PM
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I used PB Blaster in the key-hole and did the same thing, that's how I got it unstuck every time...but no matter how much I cleaned and lubed everything, it would still stick. I wound up twisting every key I own because of that cap and damn near snapped one of them off in the cap it was stuck so bad. The last time I messed with the stock locking cap, it took me 45 minutes to free it.

Currently my daily beater- 30k+ and counting the miles
07 ZX6R, lime green. Bafflectomy performed on stock muffler, disabled exhaust valve, Jumper mod, K&N air filter, PC3 with generic Euro-spec map, NGK Iridium plugs, Motul 300V & K&N oil filter, Healtech X-TRE, Drive Systems Superlite X2 steel sprockets -1/+3, Green EK chain, EBC Sintered HH pads front and rear, Dunlop Sportmax Q2's.
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