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Discussion Starter #1
I noticed a white build up around the keyhole and now it's gotten hard to open. I put a drop of oil around the outer key cylinder part where it fit to the cap. But is there a better way to fix this without dropping a couple hundred bucks at the parts counter for a new cap and key setup?

BTW looking at the pricing on parts if I could sell the parts from my Versys and get book for them I could buy HD...not an HD but the HD company. Come on TRY and tell me Kawasaki isn't gouging on parts without laughing ...come on I dare ya! :censored:
 

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Discussion Starter #3
Black Dog, I did a search and wonder of wonders for the first time it work and I found that thread.

I went out and gave the key opening a blast of carb cleaner then a shot of Loc-Eaz a friend gave me, graphite in a carrier that evaporates very quickly and it seems to be working fine now. BUT the key would go in before it just didn't want to turn. So the $35.00 E bay cap maybe in my future if I have anymore problems with it.

I know the KLR gas cap has had problem and there's a nice write up on overhauling the cap, NOT as simple as you'd think it'd be, and was hoping there'd be something along the same lines here.
 

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Somehow I don't believe that they are made to the same standard as older bikes. I never had this type of issue with the bikes I had from the 70s & 80s.
 

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Routine maintenance

About every 6 months, squirt some powdered graphite into all key locks and handlebar switches.

Keeps 'em happy and working proper for years - longer than the life of the bike, anyway.

Also works for house locks etc.

BruceC
 

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Always press down on the cap before trying to twist the key.

It relieves the gripping pressure the lock tabs have and making it easier to twist the key to unlock.
 

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All good suggestions you guys. Mine was a touch "crabby" when I got my used '08. Yep, pushing down, use two hands helps.

I also looked at my key, it had a slight twist in it. Couple light taps with a hammer against the flat spot on my bench vise and it was good to go. I had new keys made and now am very careful not to twist them.

Might be interesting to take one apart on the bench, and render it "less complicated", where as it would appear to be a locked cap, yet could be opened by just giving it the conventional twist.

Good post. I think it's one of those things that eventually catches you off guard.
 

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Hi,
I have had my first 07 V almost 2 weeks. The gas cap was working very poorly, it was hard to open with the key, it was very hard to open the cap it self and then difficult to close, everything was working very tighly.
So I took the whole cap apart and gave it a generous amount of normal lubricant (similar to WD-40) and let it dry. Now it works great, very easily and smoothly.
 

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BTW looking at the pricing on parts if I could sell the parts from my Versys and get book for them I could buy HD...not an HD but the HD company. Come on TRY and tell me Kawasaki isn't gouging on parts without laughing ...come on I dare ya! :censored:
I hear ya... I just plunked down $50 for a new OEM Air Cleaner.
 

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My cap was super tough to open, so the other day I took it off, and sprayed some WD in the pivots, then took it through it's full range of motion(not possible on the bike)- and holy crap did it make a difference!

As far as the key thing, I really don't recommend putting WD in the lock. It may be easier to disassemble the latch mechanism and clean it thoroughly. It may even need some emery cloth here and there to make those little latches slide more easily.
 
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