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Can'y open gas cap '92 Kat...Help!!!

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  • #1

    Can'y open gas cap '92 Kat...Help!!!

    I store my bike inside, so I am not sure why this is happening. I went to fill up and couldn't open the cap. I went home (had enough fuel) and sprayed the lock with PB and let it sit for a few hours. Now, even after a few days it still will not open. The lock turns and you can feel the latch start to dissengage. Just not enough to get it open. The ring on the top of the tank has 8 bolts on it, but four of them have nuts on the bottom side, that you can' get to of cource, the others are tapped into the neck. I didn't want to start prying on stuff or drilling out stainless bolts. If I could remove the ring, I think I could manually release the latch.The lock wasn't froze up or anything. I tried piutting down pressure on the cap as I was turning the key to remove any friction that might not be letting the latch retract. Nothing worked to far

    Any help would be appreciated.
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  • #2
    I had the same thing happen on my old 88' KAt. I used to have to push down on the cap to get the key to turn all the way - hope this helps!!!!

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    • #3
      Yeah , if that doesn't work , your cap is hosed . Have fun getting it out without screwing up the tank . I sure couldn't . But only 4 of those bolts up top are ACTUALLY bolts . However , once you get those off , there's still the finger holding on from the inside ...
      I am a fluffy lil cuddly lovable bunny , dammit !



      Katrider's rally 2011 - md86

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      • #4
        MD is right. Only 4 of those bolts actually need to be removed for it to come off. The other 4 are dummies. Shouldn't be too hard to figure out which ones are which.

        Just not sure how to get the cap out once you get the ring up.

        Good Luck man!!

        Greg

        COURAGE -

        Freedom is the sure possession of those alone
        who have the courage to defend it.

        First Sergeant(Ret) - US Army - 21 years

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        • #5
          Yeah , we tried to pry ours up , and ended up SCREWING the tank up bad . Popped the lip ALL out of shape . Not a good idear . I'd try drilling through the thing first if it comes to it ....
          I am a fluffy lil cuddly lovable bunny , dammit !



          Katrider's rally 2011 - md86

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          • #6
            sometimes I have to push down on mine as well.

            just be careful drilling. don't forget the fumes under that cap.
            I don't have a short temper. I just have a quick reaction to bullshit.




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            • #7
              Thanks for the ideas. I will try a few different things and let you know what happens. I guess if all else fails, I have a 10 pound sledge hammer!! Just a joke

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              • #8
                I always push down on the cap of every bike I have owned while turning the key.

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                • #9
                  Suggest you try a graphite grease in the lock and into anything else you can spray it at, then push down & turn. Might work.

                  Usually when latches fail like this, it's because of rust from either a bad overflow drain tube or from too much condensation in the tank... Once open, it would be advisable to clean & lube (WD-40, then smear with a light coat of vasoline -- use a sheet of aluminum foil over the tank opening to keep either from going into the fuel).

                  Good Luck!
                  =-= The CyberPoet
                  Remember The CyberPoet

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                  • #10
                    push down on the top while turning key. leaving the shop i bought my 98 kat from, she kept cutting off. thought i was out of gas. at the gas station couldnt get it open for nothing. got home took the bolts out and pulled out the whole rig (believe its original rig not aftermarket) corroded real bad. cleaned it real good sprayed it down reinstalled worked fine. friend of mine has keyless says he never has any problem. My guess is gas prices rise so does the water:gas ratio. cause ive had that problem alot here lately.http://www.extremebikescustoms.com/KEYLESS-GAS-CAPS.htm
                    a voice came to me and said, sacrifice that which you love the most (my girl and my bikes)
                    so i lied and gave up my girl.

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                    • #11
                      I got it! I took the 4 bolts out ( thanks for the info about the "dummies") the latch still wouldn't come loose, but after trying to turn the key and rotating the whole assembly, it finally opened. I sprayed all the moving parts real good and let it sit for a little. After an hour or so, I tried it and it worked great! I will add this to my preventative maintenance schedule so maybe it won't happen again.

                      Thanks to everyone with the help an ideas.

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                      • #12
                        White Lithium Grease also works quite well for the tank cap.

                        Once you have off the tank, take those two screws out and spray down everything you can get to. Like until you think it is too much. Then let it sit, wipe off the excess and reinstall. Will work great for a while after that. Don't forget down in the key hole too.

                        Greg

                        COURAGE -

                        Freedom is the sure possession of those alone
                        who have the courage to defend it.

                        First Sergeant(Ret) - US Army - 21 years

                        Comment

                        • #13
                          I just went with a keyless gas cap. No more worries. Mine is a vortex set up.
                          www.mopowersports.com

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                          • #14
                            good to know mines turning a little stiff on my 93,the four dummie bolts would have drove me nuts....

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