Keyless Gas Cap for '09 650? - KawiForums - Kawasaki Motorcycle Forums
 
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post #1 of 7 (permalink) Old 11-09-2012, 04:23 PM Thread Starter
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Keyless Gas Cap for '09 650?

Hey guys,

So the locking mechanism on my '09 650 gas tank doesn't work anymore and no amount of graphite or WD40 seems to have any effect. I think I might have to replace the cap.

That being said, what's a good option? Is Vortex the best way to go? I came across a thread with a really nice looking Rizoma for $200, but I can't really afford that right now. What's the best bang for the buck?

More importantly, what does installing it entail? I unscrewed the hex bolts around the tank and all that does it pivot up half of the aluminum ring. How do I cleanly remove the aluminium ring and the locking mechanism without damaging something important? And then, having done that, is it easy to install the new cap?
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post #2 of 7 (permalink) Old 11-09-2012, 05:33 PM
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Best bang for your buck? Probably a cheap Hong Kong cap from eBay.

If you have the money, Vortex is better. Do not buy a colored cap, though. If your bike sits out in the sun while you're at work or you don't have a garage it will fade in no time. I had a red Vortex cap on my last 636 than was a badass shade of pink after not too long.

The cap has to be open to remove it since the lock actually engages the tank, not the cap base. As for installing the new on, all you have to do is replace the 3 long bolts that secure the base to the cap. The other two bolts are there for aesthetic reasons only.

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post #3 of 7 (permalink) Old 11-09-2012, 08:40 PM Thread Starter
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I've got a black bike so I was planning to get a plain cap anyway, but thanks for the tip.

And I'm unable to open the current cap. I'm going to have to somehow force it off I guess?
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post #4 of 7 (permalink) Old 11-09-2012, 11:28 PM
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Black anodizing is still anodizing and will also fade. Natural aluminum is the only one that won't.

Yes, you need to open the cap. I suggest you get a lock smith if you think you have tried everything in your power to open it, but still cannot get it open.

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post #5 of 7 (permalink) Old 11-10-2012, 03:29 PM Thread Starter
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I've contacted a few locksmiths and that's what they recommend. The problem is that I'm on very low E, so if I take it to a smith and they can't get it open then I am very likely to run out of gas before I can limp back home. Anyone know the ballpark price for what a towing company would charge to tow my bike like 10 miles?
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post #6 of 7 (permalink) Old 11-10-2012, 07:42 PM
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You might have to drill the lock out.

Enough penetrating oil should free it up though

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post #7 of 7 (permalink) Old 11-11-2012, 07:04 PM Thread Starter
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I've already flooded it with graphite, WD40, and lock lube but I did order some liquid wrench penetrating oil on Amazon and expect it to arrive soon. I'll give that a try before giving up entirely.

If that doesn't work, how do I go about drilling of the cap? Where exactly do I drill? Into the part of the lock that accepts the key? Drilling in there will make the lock come off?
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