How do you clean a lock cylinder? : Kawasaki ZX Forums: Kawasaki Ninja Forum

Shumaki · 08-16-2009, 07:28 PM

I bought a '95 D3 with unknown history in non-running condition. I have spent every spare minute for the last few weeks working on it. The ony thing stilll preventing me from trying to start it is the gas tank.

I know that it was stored for a while before I bought it so I want to drain the tank and put fresh gas in to make sure I don't screw up the carbs I just spend way too much time cleaning.

When I got it someone had broken off the only key in the gas tank. I managed to get it out and solder it well enough to make a copy. It appears that the reason it broke is that there is something stuck in thecylinder. When I put the key in the cylinder, it will go in all but the last 1/8 inch.

How do I clean the cylinder so the key will go in all the way? The previous owner made sure that it was throughly lubricated.

rnoliver · 08-16-2009, 10:09 PM

The key doesn't go all the way in to the gas cap lid. Mine goes in until the flats after the last cuts in the key are about 1/8 inch from the lid. Possibly the lid and the ignition have different keys? Does the key work in your helmet lock or seat release?

Good luck!

Shumaki · 08-17-2009, 07:11 AM

The key works in all four other cylinders on the bike- just not the gas tank. and it goes in all the way on all the other cylinders. The bike has been down and the tank has no damage so I guess it's possible that it has been replaced and takes a different key.

Is that the norm? Do other people have a key that doesn't go all the way in the gas tank?

If that's the case (the tank takes a different key), how do I get around it? I don't care if it locks when I am done or not.

Shumaki · 08-17-2009, 08:04 AM

I just checked the bike and the VIN on the tank matches the VIN on the frame so the tank is original. It is possible that they replaced just the cap or the lock cylinder.

wongman1 · 08-17-2009, 09:54 AM

My latch (on the other side of the cylinder) that engages just inside the tank always sticks and needs constant lube. That latch actually got stuck in the closed position once and I couldnt turn or lock the gas cap. Thats prolly how your key broke in there in the first place. Lubing the key hole does nothing for a sticky locking mechanism.

Try spraying a little wd40 on the locking mechanism underneath the cylinder (bottom side of the gas cap), the part that actually clips and holds the gas cap to the tank. Let the wd40 sit for a few minutes then start wiggling the key to get the fluids movin and give it another shot of wd40. You will need to eventually use real lube for the internals. It seems gasoline cleans off any lube in that area.

Otherwise, take the gas cap off and bring it into a locksmith for cleaning and re-keying. Should only be around $40-50.

Shumaki · 08-17-2009, 02:01 PM

A few hours and lots of WD-40 later nothing has changed. I will keep working at it. I don't want to twist too hard. I only have one key left and this cyinder is already responsible for one broken key.

How do you remove the cap assembly? I removed all the hex screws surrounding it. Not knowing how it is supposed to come appart I didn't want to pry too hard- but removing the screws didn't seem to do anything. I guess it wouldn't make any sense to have a locking gas cap if it could be easily removed with a few screws.

wongman1 · 08-17-2009, 02:37 PM

Bummer. Not sure whats going on there. Maybe tumblers are all whacked out. Definately make another key before you do anything else. I almost went thru that issue when I got locked out of my bike... wifey had a spare for me though thankfully.

When youre getting your key made at a locksmith, call around first, most locksmiths wont carry that blank, call your local dealer to see who they deal with. Then ask them what the problem could be.

I came across this link for removing the gas cap, but sounds like youve tried it already.
http://www.zxforums.com/forums/zx-11...e-gas-cap.html

wongman1 · 08-17-2009, 02:43 PM

goto bike bandit and look up the gas cap for your bike. It will have an exploded view of how it attaches to the bike... looks like 3 screws...

Hammerhead · 08-17-2009, 03:15 PM

I still say a locking gas cap is the dumbest fuckin' thing ever put on a motorcycle. Like someone's gonna steal 4 or 5 gallons of gas.

Shumaki · 08-17-2009, 04:00 PM

Quote:

Originally Posted by Hammerhead

I still say a locking gas cap is the dumbest fuckin' thing ever put on a motorcycle. Like someone's gonna steal 4 or 5 gallons of gas.

I agreed with you even before my current dilemma.

The picture on Bike bandit is the same as the shop manual. The picture isn't very clear, but I think you have to open the door before you can remove the assembly. am not real sure what all the hex screws are for. Decoration?

Could someone post a photo of their gas door open? It probably won't help, but might make me feel better.

zx11sf · 08-17-2009, 05:50 PM

ya there is a screw under the gas cap holding it on

Shumaki · 08-21-2009, 05:19 PM

The time proven method of lots of WD-40 and beating on it with a hammer proved successful. I finally got everything back together and I am trying to start it.

A little more tinkering and it starts! It seems like the idle is a little high though. It idles at 8500. Is that too fast?

Too late to play around with it tonight. 8500 RPMs through a micron slip on won't make the neighbors happy. Would probaby wake my own kids up too.

Fanzirelligsxr · 08-26-2009, 03:10 AM

Quote:

Originally Posted by Hammerhead

I still say a locking gas cap is the dumbest fuckin' thing ever put on a motorcycle. Like someone's gonna steal 4 or 5 gallons of gas.

You never heard of people sticking shit down into your gas tank to mess with your baby? Yea, I'll take the added security.

Hammerhead · 08-26-2009, 04:19 AM

Quote:

Originally Posted by Fanzirelligsxr

You never heard of people sticking shit down into your gas tank to mess with your baby? Yea, I'll take the added security.

There are a thousand other ways some immature dolt could fuck with your bike if they want to. The only security is to keep it locked in your garage when it's out of your sight. A locking gas cap is just a pain in the ass device that's waiting to fail like Shumaki's and strand you somewhere. The first time I find a screaming deal on a screw-in cap, this locking piece of shit is gone.

Shumaki · 08-26-2009, 05:36 AM

Quote:

Originally Posted by Hammerhead

The first time I find a screaming deal on a screw-in cap, this locking piece of shit is gone.

I have never had a problem with anyone messing with any of my vehicles- gas cap security or not. A locking cap is a STUPID idea, but there are other things I would rather spend my money on than a new gas cap. If I find a "screaming deal" I am sure it will find it's way to my bike.

I was finally able to get this one open using the time proven method of lots of WD-40 and beating on it with a hammer.

When it went back together, the inside screw ended up in the spare parts bin. Now if it seizes up again, I can remove it with just the hex screws.

wongman1 · 08-26-2009, 08:59 AM

Do the ZX11s use a universal gas cap? Any cool ones out there?

I think it would be cool to have a keyless bike. Biometrics would be great - a thumbprint that unlocks everything at once. But thats just electronics that could fail.... I do see it when electric bikes are the mainstream...

http://www.tronbikes.com/2008/07/ele...a-1991-ev.html

Claude · 08-26-2009, 09:39 AM

Quote:

Originally Posted by Shumaki

...When it went back together, the inside screw ended up in the spare parts bin. Now if it seizes up again, I can remove it with just the hex screws.

Good idea! I'll remove mine in case the locking cap stop working.