Question about gas cap - Kawasaki Ninja 250R Forum
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post #1 of 20 (permalink) Old 10-16-2015, 03:32 PM Thread Starter
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Question about gas cap

So I bought my 250r about a week ago. The day after purchasing it I noticed the gas cap was open. Tried to close it and it won't stay closed, just pops right back up. I think I just need to turn the key so I can close it and turn the key again so it'll stay closed, problem is the key I have won't turn the lock. What are my options here guys? New gas cap? I'd prefer to not lose the lock, I don't like the idea of anyone being able to walk up and open my gas tank. Was wondering about taking it a locksmith to see if they can get my key to work with the lock or even make me a separate key for it, not sure if this is a possibility though.
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post #2 of 20 (permalink) Old 10-17-2015, 09:05 AM
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Take it to a real locksmith, they can rekey the cap to your key.

Does you key fit the other locks, like helmet, seat? What year is your bike?

Also while your there, have a spare key or 2 made.

A.T.G.A.T.T so I may ride another day. www.rockthegear.org

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I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike.

Last edited by Ghostt; 10-17-2015 at 09:20 AM.
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post #3 of 20 (permalink) Old 10-17-2015, 05:49 PM Thread Starter
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There's only 2 other locks on the bike, that I know of anyway, and those are the ignition and the rear seat cargo. The key works on both of those, its just the gas cap that doesn't. I guess that's what I'll do then and go see a locksmith.

My bike is an 09 250r btw.
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post #4 of 20 (permalink) Old 10-17-2015, 06:36 PM
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Okay, good luck, and don't forget to let me know how it goes.

A.T.G.A.T.T so I may ride another day. www.rockthegear.org

ZX-2R Photo gallery


I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike.
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post #5 of 20 (permalink) Old 10-21-2015, 04:48 AM
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The problem with the 09 Ninja 250 gas cap most times is lack of lube in and around the key tumbler. Over time the factory lube will dry and make the lock hard to turn. Also corrosion can set in a tiny bit if the bike is left outside.

This solution is not so simple. If it is completely stuck, the gas cap needs to be broken down to the point where the key tumbler is exposed and all parts removed and cleaned. The tumbler assembly and latch need some lube to prevent corrosion, then reassembled. https://www.250r.net/forum/showpost.p...45&postcount=7

DO NOT USE POWDERED GRAPHITE in the key hole. A little liquid lube on your key may work, even spraying lube into the keyhole, is not enough to get to the bottom of the key tumbler where it meets the most resistance while turning.

Try these things to see what works better.
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post #6 of 20 (permalink) Old 10-24-2015, 06:53 PM Thread Starter
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Originally Posted by DaBlue1 View Post
The problem with the 09 Ninja 250 gas cap most times is lack of lube in and around the key tumbler. Over time the factory lube will dry and make the lock hard to turn. Also corrosion can set in a tiny bit if the bike is left outside.

This solution is not so simple. If it is completely stuck, the gas cap needs to be broken down to the point where the key tumbler is exposed and all parts removed and cleaned. The tumbler assembly and latch need some lube to prevent corrosion, then reassembled. https://www.250r.net/forum/showpost.p...45&postcount=7

DO NOT USE POWDERED GRAPHITE in the key hole. A little liquid lube on your key may work, even spraying lube into the keyhole, is not enough to get to the bottom of the key tumbler where it meets the most resistance while turning.

Try these things to see what works better.
I'll definitely gives this a shot. Are there any specific lube's you'd recommend I try?
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post #7 of 20 (permalink) Old 10-25-2015, 04:18 AM
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If you can remove the cap itself, you can disassemble, clean, and lubricant.


Here is my write-up on how-to remove the cap diaphragm vent, but the pictures should help you,

Note: this is for a PreGen cap, but a NewGen should be similar enough.


Sounds like it could be a venting issue, no worries it's a free and easy fix,

Quote:
You need you to disassemble the gas cap and remove the two small red diaphragms, assuming this is your only problem.

The diaphragm gets hard and losses it's flexibility and gets stuck, and doesn't allow proper venting.

IMHO this modification should be done regardless to prevent future problems whatsoever.

They are ment to vent the tank, but in the case of an accident not allow gas to leak out, but more often cause problems then they fix.

Here are some pictures to help you.

The plastic piece houses the two small red diaphragm pieces, this one being mine, they are already gone, and you can leave the plastic piece out all together, as I'm going to do now.

Some things to watch out for are, there are 5 small springs under the round collar, and a small round collar as well on the locking mechanism, don't lose any of them.

Good luck.










A.T.G.A.T.T so I may ride another day. www.rockthegear.org

ZX-2R Photo gallery


I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike.
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post #8 of 20 (permalink) Old 10-25-2015, 06:00 AM
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Originally Posted by Samfb24 View Post
...Are there any specific lube's you'd recommend I try?
A little light grease goes at the bottom of the tumbler if you are able to get to it.

WD-40 or Dupont Teflon multi-use, make good lubes for this purpose.
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post #9 of 20 (permalink) Old 10-25-2015, 08:01 AM
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Penetrating oil, but I'm old school and use powder graphite, as wet lubricant will attract dust, dirt, etc.....

Lately I've been using Dri-slide Bike Aid lubricant, it goes on wet, but dries. I use it on my all cables, and locks.

Quote:
Bike Aid creeps into the smallest spaces including the pins on the chain and cures to leave behind a dry film of moly. This unique dry film won't attract dirt or dust, is highly resistant to water, and prevents rust and corrosion It is the perfect lubricant to use on brake and gear cables, derailleurs, front and rear brake pivot points, shift controls, chains quick release nuts. Prevents cable freeze up. It functions properly in temperatures from -20* F to 750* F.
http://www.drislide.com/

Bike Aid Dri-Slide 4oz. Lube with Needle Nozzle https://www.amazon.com/dp/B001F2Y25G..._G6plwbQ6YQS98

To each his own.

A.T.G.A.T.T so I may ride another day. www.rockthegear.org

ZX-2R Photo gallery


I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike.

Last edited by Ghostt; 10-25-2015 at 08:09 AM.
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post #10 of 20 (permalink) Old 10-26-2015, 06:51 PM Thread Starter
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I was thinking about spraying a little wd40 down the gas cap key hole to see if it helps. Hopefully I can find that bike aid lube locally. Otherwise I'll have to buy it online and wait for it to arrive.
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