VDR 1500 1999 Original locking gas cap will not open

[lefecious]

Had it been sitting for a while?

Does the key turn all the way or does it get stuck?

I had the same problem after my bike sat unused for a couple years. The latch was stuck because of all the corrosion and buildup of gunk.

Here's what I did.

I sprayed some graphite lube into the key hole, then
I pushed down on the cap to relieve the pressure on the latch. Then while holding it down like that, I just stick the key in and wiggle it and turn it as far as it would go about a million times. It's tricky because I wanted to turn hard but also not so hard that it breaks the key. Eventually, the key turned all the way and I got it open.

There was so much crud on the other side of the gas cap, I still haven't gotten it all off. This was just last night.

[indue]

I had the same problem but it was due to my insertion of a viton o-ring in the wrong position. I had to pry the cap off. Unfortunately, I used some towels under the pry bar/screwdriver and it left a small dimple in the tank. If I had to do it again I would use a 1/4" piece of plywood with towels underneath. Then what I did after I took it off was to turn it over and drill two small holes through the retaining screw holes up and through the top of the cap. Then I used 4-40 screws and nuts to hold it together. The metal of the inside was somewhat tweaked so I also had to straighten that out. Once it was together, it worked fine. My key still worked in contrast to your predicament. Push down on the cap very hard and try to work your key again. Try a little penetrating fluid in addition to your graphite. If it doesn't work you will need to get it off so that you can replace it. Good luck!

[RLH]

Thanks for the info I will check it out!

[Bucko]

Gas Caps are still available from Kawasaki (51049-1121 for my 01) for about $75.  Not sure how the key thing works with new caps - maybe they come with a new key (if so - the fiche doesn't show it).

[RLH]

My locking gas cap will not open with original key?  I don't know why? Works fine as ignition key but no longer works on gas cap lock. I have tried graphite-no go.
I am afraid I am going to have to pop the lock but I can not find a replacement gas cap to fit. Any ideas about where to find a replacement gas cap to fit. Preferably a non-locking cap?