Fuel cap seized - taking apart fuel cap and cleaning - Kawasaki Versys Forum
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post #1 of 9 (permalink) Old 02-29-2020, 04:43 PM Thread Starter
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Fuel cap seized - taking apart fuel cap and cleaning

I have been having issues with the fuel cap over the past 6 months. The key would go all the way in the locker but it would not turn all the way to open the fuel cap. The temporary solution was to spray some silicone lubricant and after 5-10 minutes it would eventually turn and open the cap. Today I decided to take apart the mechanism and clean it thoroughly. To remove the fuel cap you only have to unscrew the two bolts at the bottom and one at the top. The other two are for aesthetic purposes.

Here is how the mechanism looked like





All the parts were covered in white stuff. The locking mechanism consists of two tabs that slide in and out inside a rail and a spring to pushes them apart. I cleaned off the corrosion using some fine sandpaper and steel wool, sprayed them with silicone and put everything back together. Overall the lock now turns a lot smoother than before. No more worrying about breaking the aluminum key. However the key does not turn back when you open the fuel cap, I am suspecting that the key cylinder has some corrosion as well and I would need to remove it and clean it too.

The job took about 30 minutes and is an easy thing to do.
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post #2 of 9 (permalink) Old 03-01-2020, 06:23 AM
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That's the most corrosion I've seen for a fuel cap!
Was it unused for 5 years or what?

Normally, my only maintenance there is to put graphite in the keyhole and that's about it.
I fuel up high enough that this mechanism is soaking in fuel. Never had any corrosion since.

Any water in the gas is at the bottom, but if the tank is not full, you have water in the air. Any cooling below dew point will make condensation and cause this crap on long term. That would be winter storage. That's why winterization begins fueling up to max. Just don't fill up too high if your bike will be indoor; you probably get fuel in cold days and if it warm up indoor, it will expand and overflow and stink up your garage. Now, how do I know that... :-)

Tip: fill your last 2 tanks with non ethanol (often super 91) to avoid ethanol in system. Stabilizer is not mandatory for only 3-4 months of non-ethanol but won't hurt. Stabilizer may make things worse with ethanol fuel. See projectfarm's clip:

Last edited by dddd; 03-01-2020 at 06:26 AM.
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post #3 of 9 (permalink) Old 03-02-2020, 05:30 AM
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Thanks for sharing.

I fill to the brink to keep the cap lubed. Never had a problem so far.

DON'T LEAVE YOU TANK HALF FILLED AND PARKED FOR A LONG TIME.
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post #4 of 9 (permalink) Old 03-17-2020, 09:00 PM Thread Starter
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I live in the NorthEast and I ride all year around. The bike is parked outside and exposed to rain, snow and extreme cold at some point during the winter. I am not sure how to avoid corrosion on aluminum parts in these situations.

If you only add graphite lubricant to the lock it maintains the lock but it doesn't take care of the locking mechanism. Many people on this forum were complaining that although the key goes in and can partially turn, the fuel cap does not open. Remember to check and clean the locking mechanism.
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post #5 of 9 (permalink) Old 03-27-2020, 12:36 AM Thread Starter
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I found this PDF that someone else wrote about how to take apart the fuel cap lock mechanism and lock cylinder and plug, and clean them. This for a different bike but most of the parts are very similar to our bikes.

http://www.xj4ever.com/gas%20cap.pdf
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post #6 of 9 (permalink) Old 03-27-2020, 05:15 AM
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Thanks for sharing the PDF file.
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post #7 of 9 (permalink) Old 03-28-2020, 12:30 AM Thread Starter
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I tried to take lock cylinder off to clean it but I am having trouble removing the lock cylinder from the housing. I can see what I think is the brass retaining clip but I can not push it back in. I used a tiny flat screwdriver or a small thin scissors but no luck.



Any suggestions? Is there another way?
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post #8 of 9 (permalink) Old Today, 01:08 AM
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With a slightly curved small screwdriver behind the brass clip, push it down (as seen on photo) towards center of fuel cap, while pushing lock cylinder out... A little shot of WD-40 might help.
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post #9 of 9 (permalink) Old Today, 11:07 AM
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How To Eventally

Quote:
Originally Posted by nikosb View Post
I found this PDF that someone else wrote about how to take apart the fuel cap lock mechanism and lock cylinder and plug, and clean them. This for a different bike but most of the parts are very similar to our bikes.

http://www.xj4ever.com/gas%20cap.pdf
As in the title, your post could help hundreds
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