Why is everyone so hell bent on telling him it's not jammed? Obviously someone jammed something in there. I'm sure he would have figured it out by now if it wasn't. How he wishes to proceed is his business, but for God's sake please stop telling him it only goes in half way... that's what she says!

 

gooooooooooooooooooooooooooooood!!!!!!!!!!!!!!!!!! !!!!!! :d

 

Okay. Did you actually try taking it to a locksmith for a quote to open it? If it isn't too expensive it might be a good thing to do. Then you could maybe tear the lock apart and make it work with any key. I didn't look at the Kaw parts site, but you may have to buy the entire cap to get the lock. Of course there's always the used path since that cap was used on so many models.

Good fortunes to you in dealing with it, even if you have to buy a new one the bike was still a good buy.

 

How can you give up on his gas cap so easy? I'm to cheap to give up and buy a new one so soon. It's too easy to just hack it off and buy a new one when it's not your money. I still have a few more weeks to watch him fiddle with it. It's more impressive to say you fixed it than to just replace it. It's more sporting.

 

I know I'm the same way. I'll do anything to try and fix something before replacing it. But sometimes that's all you can do.

stabone, since the tank's off and is probably free of gas fumes by now why not take it into a locksmith and see what he has to say.

 

my vote is to drill the plastic near the screw and unscrew it off....replace the tumbler after...hammering a screwdriver or other objects did not work to open the gas cap for me...

 

Ok, so yes there is definitely something jammed in there. I was planning on just drilling the lock part on the cap. The lock part is about 30 bucks, plus whatever to get it set up to work with my key, the whole cap is about 80. I like the idea of taking it to a locksmith now though. If I could find one around here I might do that. Right now I'm getting over a severe cold,, so it's going to have to wait a little. I'll let you guys know though and thanks for any input.

 

I drilled the lock out, but still couldn't open it. The one picture shows what the cap looked like after drilling. The next plan was to try and get the pin out of the hinge. A friend was trying to hold up the plastic so I could see the pin, but put a little too much pressure on it and plastic went flying off. So now the screws were exposed so I unscrewed it and the cap came off. It seems the cap was really corroded and that's why the key wouldn't unlock it. Anyway, it looks like I'll be getting a new gas cap.

 

Geez, what's the inside of the tank look like? I hope it's not as bad as the bottom of that cap. Glad to see you got it off. If the tank looks bad, then you have a great excuse to get the 3 gallon IMS tank. It comes with a new cap too.

 

The tank actually looks pretty good. I'm still debating on what I'm going to do.