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GAS CAP PROBLEMS! Dammit....

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Old 08-06-2011, 05:47 PM   #1
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GAS CAP PROBLEMS! Dammit....

Ok, friends... in need of some:

2008 kawi zx6r, went to fill her up at the gas station today and the key won't open up the lock. With fuel light on, made it home and tried everything I could think of; twisting, pulling, lubing(wd40), flipping key, wiggling key, key-fucking the lock, hitting the key (with my hand) into the lock, and I even tried taking the allen bolts out, but as you all probably already knew you can't take the assembly off with out it being unlocked. I'm so pissed about this...its such a small stupid problem, yet it fucks the whole bike over since you can't get gas in it. All they had to do was was make some sort of button that only works when the key is in the ignition but not started....this problem could be totally avoidable. But anyways, to me it feels like there is something physically obstructing the key from getting down into the lock, I'd say the last 1/16" or less.... It's ridiculous.

Any help would be appreciated.
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Old 08-06-2011, 05:59 PM   #2
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sounds bad but that happened to a firends honda and he had to drill out the lock and get a new cap
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Old 08-06-2011, 06:01 PM   #3
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Wow.. Lucky you got home dude.. Try getting a air gun and spraying high psi into the lock to see if some of the crap will come out? Does your bike live outside and have you got a spare key to try?
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Old 08-06-2011, 06:02 PM   #4
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hmmmm

Maybe try using an air compressor (if ya got one) or one of those keyboard air dusters (if ya don't) to see if its something small that will just blow out? I used my air compressor on the inside vent on the cap to clear it out and it worked perfectly- no more pressure build-up. Hopefully it isn't jammed too much in there from the key- wish I had better advice
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Old 08-06-2011, 06:02 PM   #5
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After this, I want nothing else but to get a new keyless cap, but I can't get it off and I don't know how to effectively drill out a lock
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Old 08-06-2011, 06:08 PM   #6
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Unfortunately, it does live outside :/ I'm planning on trying to use an air compressor like yall havr suggested, however I have my doubts as to how that will work... That wd40 went in, and out, of thaf lock with a good amount of pressure and it didn't take anything out. I do have a spare key, good thing I do because I ended bending the original and it didn't want to go back into the ignition at the gas station! Lol thank god I didn't break it, I just bent it back and went on my way.
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Old 08-06-2011, 06:12 PM   #7
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What could it be, and how could it be fixed, if there isn't some sort of debris down inside?
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Old 08-06-2011, 06:18 PM   #8
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a very large drill bit right in the center on the lock and just be prepaired to drain the gas tank
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Old 08-06-2011, 06:20 PM   #9
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hmmm

Well if it isn't debris (I would also try like a paperclip or something skinny to see if you can pick it out) then I would guess that the cap would have to get drilled out and replaced as already mentioned. Probably not the answer ya want to hear, but I can't think of another way
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Old 08-06-2011, 06:23 PM   #10
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Are we talking 'large' as in it needs to remove the whole cylinder, or 'large' just to get inside the keyhole? What do you do once you've drilled it? How do you make the locking mechansim release? And finally, when you say drain, should I just syphon what fuel is left in there, or are you talking removing tank from bike and completely emptying?
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Old 08-06-2011, 06:32 PM   #11
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large as in the size of the entire key hole or about 1/2 inch, drill it all the way through that and the locking mechenism should release, notice i said should cus i have no idea, then remove the entire gas cap, take the tank off the bike, and flush it to get all the metal shavings out. ive only heard of friends telling me how to do this so id definitly do more research on it.
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Old 08-06-2011, 06:57 PM   #12
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Try pushing down on the cap and turning the key. Worked for me once.
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Old 08-06-2011, 08:21 PM   #13
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That used to happen with my old bike. But it got totaled before I could figure out why or how to fix it, so I don't think i can offer much help. I have a vortex gas cap on my tank now. It doesn't use a key, just unscrews.
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Old 08-06-2011, 11:22 PM   #14
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I have tried pushing down on it, in fact it was the first think I did. It's always been a little stiff, so that was something I've always had to do anyways. Thanks for the posts, guys. Anymore ideas, keep em comin!
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Old 08-06-2011, 11:28 PM   #15
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Have you tried tapping the lock while turning? Drilling it out would be my last chance for it.. Graphite power works on locks too.
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