So I just bought a beat up 09 for a decent price. It needs some work but the first thing is getting the gas cap off. The key won't go in all the way in. Any suggestions?

 

Pretty sure it doesn't go in all the way, but about 2/3 the way, then try turning it gently.
If it doesn't turn, spray some PB Blaster or WD-40 on the key, insert it and jiggle (gently).

 

Key isn't going in very far. Tried wd40, just won't go in. Possibly something is broke or jammed. I just want to get the cap off. If I have to get a new one or am not able to lock it, that's ok. I just don't want to mess up the tank. Any good way to do this?

 

Someone on here had their's jammed. Hopefully they'll see your post and let you know how they got it open.

 

Does the little tab let the key in a little bit? try opening with a screw driver and flashign a light inside and then using pb blaster directly to any trouble spots then LIGHTLY clear debri with a screw driver.

 

Once I couldn't get the key all the way in and turn it. Kept trying, and finally pressed down on the gas cap and was able to get the key all the way in and turned. Hot damn.

 

I'll have to try some more tomorrow, I'm really not sure what the problem is.

 

You say you just got the bike. Have you had the cap off before? Does the key fit the cap?

Refresh my memory guys...is the stock cap actually "keyed" or does it just accept any Kawasaki key design to release. I've never, ever kept the stock tank on any KLR or KLX I've owned over the years long enough to remember how the OEM cap works. Something in my foggy memory makes me think the cap isn't really keyed exactly but does have to have a Kawasaki key design to open it up. Anyone know for sure?

 

No it is keyed, but you only need to insert the key maybe half way. Most likely someone vandalized it by jamming something in there.

 

Yup, that's what I'm thinking. Still need to get it off though. Anyone know if I could get an aftermarket cap somewhere, I figure I'm going to damage this one too get it off.