Gas Cap Stuck On Kawasaki Motorcycle Gas Tank Won't Unlock

Gas Tank Won't Unlock Gas Cap Stuck On Kawasaki Motorcycle. Some times its not just a key and lock issue when involving a gas cap. There was no issue witht he lock or key. The latches had corroded and frozen in the locked position. There was no other option accept to forc the cap open. All Most an hour was spent trying nondestructive solutions like lubrication and tapping with dead blow hammer and vibration we all used before destroying this gas cap.
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[@rukusho2893]

Everyone, this goes for almost every bike. There are only two ways of solving this. A. wd 40 method which can take hours-days of patience waiting for the lubricant to make its way to the wings or B. (For Kawasaki's)Drill onto the top right corner where there is a Phillips head. Undo the bezel and that Philips bolt and you're in. None of this prying (in the video) required. This happens as a result of bikes sitting in rain or sitting with fuel still in the tank for longer periods of time. Don't try to force it open with the key - ease into it, because you risk either bending the key or snapping it. I've seen all sides of the spectrum.

[@alilGoat]

Can you explain? Drilling where? Top right of what?

[@horehay85]

what about Yamaha... my r6 is in this same situation

[@alilGoat]

@@horehay85 If its corrosion causing the issue, if lubing doesnt work... I had to snip a key as short as possible, shove it in the hole, then pry open with a screwdriver to break through the corrosion on the wings. I'm glad I didn't attempt drilling through the top right, the hole was there on the cap but my model bike didn't even utlize a screw there lmao. Not all kawasaki's have a screw there for removal.

[@horehay85]

@@alilGoat I think it's the wings that wont move I've been soaking it with PB buster and working the key, I'm gonna try taping it with a rubber mallet next

[@horehay85]

So I'd like to point out that drilling kinda worked on mine gas cap... I was lucky enough to drill threw and get the screw undone... when I tried to pull up the wing that grabs the gas tank itself was still holding on.... the gas I ended up breaking it off while trying to pull the cap out of the tank.. I had to fight it a bit but it came out in pieces... I replaced it with a new cap that I bought and its perfect

[@misterg4089]

Been trying the other methods tapping on gas cap , lubricant sprays for a whole month you are right whatever u do on top ISNT gonna help if that lock is seized up from corrosion I’m gonna have do your method seem like it’s no other choice other people were able to open up theirs the other ways bc their situation probably wasn’t as bad as mines and yours

[@bluefretjake4353]

Cool video dude so what I added. I used a cheap spring loaded center punch from harbor freight to push out the dowel on the cap hinge to that mounting ring had to use vice grips to pull it the rest of the way. Center punch put the dowel back once I cleaned the gas cap and now it’s all good to go. Not so destructive

[@xXbugatti]

I had this same problem I used rust penetrant spray and in about a minute I could open it. I sprayed the inside wings while twisting the key and now it opens better than when it was new

[@wr2956]

How’s about a bit of preventative maintenance people? You grease your chain every 300 miles or so, so why not spray a bit of chain lube into the fuel cap lock once a month and turn it with the key a few times to work it into the mechanism to keep it from corroding? Works for me, never had an issue adding fuel 👍

[@steventeal5460]

Get a hammer. Seriously! Hello fellow cycle-heads. My friend neglected his ride for 3 years(yes, shame on him). Gas cap key would turn but not open. I got a small rubber mallet and tapped the gas cap while turning the key. Three taps was all it took. Vibration lubricant, lol. Good luck friends...now get out and ride 😎👍

[@bcampera]

I am going to try that tomorrow! Thanks for the tip!

[@edwardalatorre2206]

thanks for getting too the point.

[@jeffreyallen4385]

Worked well after I took off thanks.

[@megapet777]

I think that's my issue too, but the mechanism moves very little. So I can open the gas cap, but it's very hard. What should I do?

[@zeekgranston5719]

I have the same issue with my Kawasaki Zzr, and I have the quick release gas cap

[@diegojd9544]

lucky i haven't got to that point, today i got my tank open after messing with the key a bit, now that its open though what can i use to clean the wing?? i see 2 screws that i'm sure will remove the wing, but still not sure what is gas tank safe to use to clean the wing any suggestions???

[@elroyrigsby-leday7250]

Did you end up cleaning it?

[@ginoyap8172]

Dude, really helped! Thanks alot 👍🏻👍🏻

[@jennyv4180]

ok.. so can we say recall!? this just happened to me, that's why I'm here watching. I'm so pissed and frustrated that I don't even know what to do..gonna try again tomorrow...

[@Ullalandnz]

It work for me. needed to twist the gas lock whit power and it`s finally snapt

[@drwombat]

Hey how did you get the barrel out? I'm dealing with the EXACT SAME ISSUE IN TROPICAL CLIMATE except my key won't turn 100% only turns about 75% before those "wings"/latches stop the lock barrel from moving any further

[@soldierjonny]

mine wont open ethier!! kawasaki ninja 650f

[@user-dz8zc6fx6n]

1:40 we know see this does come out.. but how?

[@diegoherrera1090]

were the wings seized in the extended position or the contracted position? i think thats a better way to ask the question.

[@diegoherrera1090]

How did you just "pry it open" with the wings seized? Aren't the wings directly in contact with the gas tank?

[@diegoherrera1090]

I have a 2006 CBR 600RR with the same issue

[@elizabethb882]

Some locks only have one wing, in which case, tilting toward the wing and up will free the cap (this works on an 05 ninja 250). If you have two wings, try to get wd40 into one of the wings as you pry up and push it in as you turn the key (all while keeping the pry in place). This is more for anyone that reads it than just you sine your post is old. Hold it helps.

[@psylentsage]

My wings are frozen atm most annoying thing in the world when u first find out and need gas!

[@jeremynading2006]

I have a 90 Yamaha yx600a with the same issue but it stuck in the locked position. am I going to have to do the same thing? when I got it it had two keys and the key that works in the ignition was jammed in the gas cap got it out and the other key won't work on anything I have tried either of the on the seat lock only being didn't need to.

[@lolojones5073]

Please start recording at start of problem.... I want to see HOW exactly you pried it off. Thanks though.

[@bvcxzgt5451]

He didn't even explain how he got it off. Pried up the ring, then we could get it off. WTH does that mean?

[@miketonyes4493]

how did you get the cylinder out of there? i work at a lock shop and a customer came in with yamaha yz 750 and we need to get his cylinder out of the gas cap without fucking the whole part up.. any helpful words of wisdom?

[@waynewinton]

use a hook pick to reach into the bottom of the lock and depress the retaining detent while pulling on the cylinder gently. this will remove the core it it has a removable core.

[@napdacatcher]

You say how you get the cylinder out but how doy you get the whole gas cap out ?

[@XmrknightX]

he didnt even say that he drilled the bolt holding the whole thing to the tank vout a 1/4 inch in

[@Jacknife-io8ok]

but thanks for showing me how to get the cylinder out hehe

[@GhostofCicero]

My cap is about 4 months old and has seized up on me. About 3 weeks since I last fueled up and it was fine then.

[@stevetucker8169]

SO?

[@GhostofCicero]

@@stevetucker8169 So, don't let the fuel get low. I only have the problem when the fuel is low. I keep it lubed too.

[@cesarluna1054]

I cant find how to remove the cylinder...do I just pick it inside and it comes out?

[@misterg4089]

Just picked up a 2002 Kawasaki zx12r that has been in storage for over a decade im experiencing now a seized fuel tank lock

[@DivanProdOfficial]

you don't have to destroy the bike...just put something on the gas cap (to not scratch it) and hit it with a hammer. Hit it around the keyhole and on the keyhole at your medium velocity(just enough so you wont bend the metal). It might not work from the first hit but keep trying. The vibrations will crack the calcareous deposits from the pins.

[@ThePatrakeeelis]

DUDE I love you 😂😂 Was about to break into this thing but a few taps with a hammer and drift punch it opened right up 🎉🎉🎉

[@DivanProdOfficial]

@@ThePatrakeeelisJust don't forget to put a towel over the gas cap so you won't scratch it with the hammer :D

[@francisgoldstien6153]

spray a little CLP on it now and again. and don't use gas with ethenol in it ,if you can help it.

[@user-hf9ls2fg6s]

Same problem happen in my two Kawasaki moto. Bad news...

[@TexasJim]

I have found this had happened to me on one of my cycles.

[@waynewinton]

Texas Jim it sucks!

[@waynewinton]

Visit wayneslockshop.com/ For More tips and tricks for the Locksmith Industry

[@daye5900]

Just happened to me today on a 300 ninja 6 months old. Key wouldn't turn the lock as if i were using the wrong key. Poured some wd40 into the gas cap lock and nothing. After about an hour calling locksmiths i tried to unlock it again and boom. Able to fill her up and ride But i am going to be visiting kawa dealer about this issue, don't love being stranded and not able to put gas

[@budgiecat9039]

wd40 usually works for me. Shits annoying though

[@beewills9492]

oh god.. I pulled my lock cylinder out of my cap the last time I filled it up.. bought a whole new gas cap recently. I was under the impression that if I take all the bolts off of the silver ring it should just come off completely. oh jeez I hope my thingys didn't seize up 😑.

[@waynewinton]

🤔

[@JC-ok1kv]

i am experiencing this on my kawasaki zx6r. i believe my locking wings are seized up and keeping it from turning the key. how did you manage to pull the whole core out with the wings still locked out?

[@waynewinton]

grab the retaining clip in the Bottem of the lock with a pick and remove

[@eddiekawasaki600]

www.ninjette.org/forums/showthread.php?t=102020

[@SNOWRYAN8]

Yeah, same problem with my 07 ZZR. I removed the silver lining, but can't get the lock out. It won't come out...so how do I get the rest of the cap out? I tried to drill it out and think I might have drilled too far.

[@waynewinton]

Oops. Should have called a professional from the start.

[@daye5900]

SNOWRYAN8 i believe there are one or more screws under it. Not 100% sure tho

[@AlexSol1]

Why didn't you just drill a tiny bit to remove the hidden screw instead of breaking the ring?

[@delwood77]

This is a ZX6R which doesn't have a hidden screw. What looks like a hidden screw on these is actually just the drain tube for water that gets around the cap area to drain down through the tank. How do I know this? I saw what I thought was the secret screw on mine, just peeking out around the edge of my cap, so I drilled through at that spot and ended up destroying the drain seal, so now if I were to wash my tank, water would now leak down into the fuel overflow pipes and fill up the carbon canister, instead of being diverted through the tank and onto the ground. I ended up taking my tank off, draining the fuel, removing the fuel pump and turning the tank over and soaking the latch with penetrating oil from below. After soaking for a couple hours, a small wrench on a freshly cut key worked to wiggle the lock back and forth and finally free up the "ears". I unfortunately drilled my cap before I saw this video: kzbin.info/www/bejne/lWXcZ4qOj7xghJI

[@d.v.8750]

THIS IS ESSENTIALLY WORTHLESS. ANOTHER VIDEO SHOWS HOW TO GET IT OPEN.

[@Jacknife-io8ok]

try some di-electric grease

[@zx6rrnewbie]

I found an easier solution! Use an orbital sander to vibrate the gas cap. First loosen up the three allen head screws, only three of them actual bolt the outer ring down on my 2006 ZX6R, the other two are dummies. After loosening up these bolts I placed a sheet of rubber I had laying around on top of the gas cap. Then I used the orbital sander to vibrate the gas cap. Took me about two minutes, and it worked! I was able to open my gas cap again. Easy solution and does not destroy your gas cap. Check out this video. kzbin.info/www/bejne/b3S8mnahZ8ypadk

[@freemarketjoe9869]

You didn't show at all what you actually did to get your results and you moved the camera around so much i couldn't see anything anyways. I have the same trouble but learned nothing from this. A slow step by step explanation would have been helpful. I guess i just unscrew the bolts and break the thing off, since i see that is what you finally did by the pieces inside the tank lip. Once i get the damn thing off, i'm going to put a non locking cap on. Who steals gas these days? Nobody!

[@omarcarranza8973]

can I pay you to do mine?

[@marlincastleberry8799]

Didn't help me at all. I put in a 99 Kawasaki and this came up.

[@jeremynading2006]

I have a 90 Yamaha yx600a with the same issue but it stuck in the locked position. am I going to have to do the same thing? when I got it it had two keys and the key that works in the ignition was jammed in the gas cap got it out and the other key won't work on anything I have tried either of the on the seat lock only being didn't need to.