I'm 100 miles from home, on empty, and now that I've stopped to get gas I've discovered that my gas cap lock is stuck. Key won't budge the lock, and removing the hex bolts in an attempt to remove the entire assembly didn't work. Any ideas??

Message from KAK from a few years ago:

"Just thought I'd mention this because some guys say they've had problems with "stuck" caps and even damaging their keys. Some of you may have an actual problem but I have a method that some of you may not know about. I believe a lot of the problems are caused by pressure build up. If you try to open the cap under pressure by simply turning the key to 3:00 and lifting up, the pressure will cause a jamming effect on the key. So it's simple; just press the front area of the cap down moderately with your left thumb first and then turn the key to 3:00. As you lift you remove pressure. This relieves pressure from effecting the smooth operation of the key.
Works for me."

Hope this helps... -bg

* Last updated by: bgordon on 8/9/2012 @ 8:16 AM *

Thanks...

I normally press down on the cap to relieve some pressure off the latch and it works smoothly, but now it's as if the lock is welded...no movement at all. I'll probably put an aftermarket non-locking lid on it to prevent being stuck in the future, but gotta first have to figure out how the get the cap off.

* Last updated by: kb377 on 8/9/2012 @ 8:23 AM *

Tried spraying some WD40, Liquid Wrench, or (my fav) PB Blaster into the lock?

Mine was stuck and powdered graphite was not working as well as it had in the past when the lock got sticky. I used Seafoam Deepcreap and that did do the trick after a good soaking in it.

I still recommend going to an aftermaket cap. There is at least one made for the 14 that has a lock. the others are quarter turn caps. The new Vortex is a very nice looking one.

Finally got it home...wife came and picked me up, went back with the truck/trailer and got it. It's been sitting in the garage for an hour soaking with penetrant. So far, still no budge with any of the three keys. Looks like I'll put an aftermarket cap on to prevent having another trip ruined (left out at 5a this morning headed to Deals Gap and planned on returning late this evening).

Now, any ideas how to get this thing disassembled? Once the bolts are removed, it will only rotate a few degrees either direction, and won't lift out at all. At this point the lock is FUBAR'ed anyway, so I'm not worried about tearing it up.

I just ordered a Vortex V3 cap, then went back downstairs to work on getting the stock cap off. I stuck the now mutilated/twisted key in and beat the ever-living crap out of it with a hammer...finally got it to unlock. I lubed it down with some moly dry-film lube (bike cable lubricant) and it works nice and slick. I'm still switching to a keyless lock to avoid being stuck in the future.

Sheesh...you think maybe it's the ethanol or something gumming up the works.We're mostly Ethanol free here(91 anyway).My 07 lock worked great for 4 years.

* Last updated by: Grn14 on 8/10/2012 @ 12:08 AM *

Had this same problem with my ZZR and had it start to happen with the ZX already so took steps to remedy the problem.

It seems Kawasaki is still using the same fuel cap they have been using for over 10 years, time this was updated???

Neil

I've never had one stick on me, but I still think a locking gas cap is the dumbest fucking thing ever put on a motorcycle. My 2010 F150 and 2011 Taurus don't have ANY gas caps, just a vapor door in the fuel neck. If someone wants to steal fuel, they're gonna do it from a 26-gallon tank rather than a 5-gallon tank. And I don';t buy the vandalism prevention angle at all. If someone wants to fuck your bike up, there are lots of ways other than putting something in the fuel tank.

My 2008 ZX14 gas cap always unlocked, no problems. And we've had 10% or greater ethanol in Maryland gas for a decade, I think.

My 2012 Connie has a gas cap with a flip up cover over the keyhole (standard stuff) and seems to open stiffer than my ZX14, but its only 6 months old so time will tell. But it opens quite easily enough not to put a strain on the key.

Mine always seems to open easily enough, but is a little balky when it comes to closing. I ordered a non-locking, screw-in cap, because the lock is totally unnecessary anyway.

@Neilp:

What are you showing us a picture of? Looks like a "vapor door" type that Danno mentioned for autos.

Where did you get it?

Thanks...

Got this off Fleabay, here is the link.

http://www.ebay.com/itm/370528033726?item=370528033726&viewitem=&sspagename=ADME:X:AAQ:MOTORS:1123&vxp=mtr

Hope this helps.

Neil

I think the confusion is, how do you grab that and twist it off? Here's the one I have coming:

http://www.ebay.com/itm/Silver-Billet-Fuel-Tank-Cap-Kawasaki-ZX10R-ZX6R-07-08-09-ZZR-1400-ZX14R-Z750-Z10-/200774198109?hash=item2ebf13235d&item=200774198109&pt=Motorcycles_Parts_Accessories&vxp=mtr#ht_1694wt_1037

Neil, looking closer at your photo, I can see the indentations in the cap where you get a grip.

I think I'm out of luck, again.

No caps for 2012 ZX14R's, unless you can tell me they're compatible?

Mine is a 2012, the indentations there are 3 let you hold it with your fingers while pushing down and then turn it 180 degrees, then lift the cap out. Seems to work OK and is alright for the price!
I may change this down the track!

Neil

Also consider filing your locking dogs so the cap can be closed and locked without using the key....just close it down tightly and viola!

@Neilp:

I looked at this three times before I posted this... I also have a 2012, but with the OEM locking cap still in use.

That OEM cap appears to be "off-center" from the 3 mounting holes. That is, I unlock the cap, swing it open, and then I look into the tank opening (the hole where the gas filler is inserted). The cap on it's hinging plate is definitely off-center to the opening. The hinging plate and it's mount (the circular metal disk that uses the three mounting holes) also appears to be offset from the tank opening, using the three holes that also appear to be offset from the tank opening center.

Everything, including the three mounting holes, appears to accomodate an off-center gas cap.

So, what I dont understand is, why the symmetrical (centered) non-locking replacement gas cap fit onto your (2012) tank? The pictures appear to show the non-locking replacement centered between the three holes where it would mount...

I believe you that it did indeed work, but looking at mine I cant fathom why it did.

@ninjawarrior:

What are the locking dogs you write about? How do you get it back open without using the key (you can't, right?)?

I think you're describing just closing and locking it without needing the key to do so... Actually, that's what you've written, huh?

So, I think this mod you've described does not adress the OP's issue, does it? Or does it? (It still has a lock in the cap).

No nastiness to the voice, I'm just trying to understand and learn...

Just replaced mine tonight with the billet screw-in type.

For Sale: 1 ZX-14 locking fuel cap complete with key. Make offer or buy me a beer and pay shipping, just get this thing out of my garage.

Eliminated my problem about a week ago...got the Vortex cap in and installed.

* Last updated by: kb377 on 8/22/2012 @ 9:31 PM *