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Old July 5th, 2015, 04:30 PM   #1
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Ignition Key Will Not Come Out of Gas Cap

When refueling this afternoon on my way home, I filled the tank, and then found that when I put the cap back on, the key would not come out of the gas cap. I worked with it for about ten minutes and then a fellow who had been watching me came over and asked if I would like for him to try. Since I've got two left thumbs and am a total klutz with repairing or fixing anything, I said "sure". He tried repeatedly with absolutely no success either. When you remove the cap from the filler neck the key will turn as it should and come out of the locking mechanism. But when you put the cap into the filler neck and try to turn and remove the key, it doesn't seem to turn as far as it should and it will not come out of the lock. Fortunately, he had some tape in his car so, we used tape to cover the filler opening, and with the cap stored away I rode home, more than a little frustrated.

Has anyone else had this problem? My guess is that something has gone wrong with the locking mechanism in the cap. The key works fine in the ignition and it opens the side cases (not real smoothly but it does open and lock them).

I'll take it to Duc Pond Motorsports on Tuesday (July 7th) to see if they can either fix the problem or replace the cap, but I thought I would post the issue to see if anyone else has had this problem.

Thanks,
David H (hetrida)
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Old July 5th, 2015, 05:44 PM   #2
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Chances are the cap isn't seated in the fully closed position.

With the cap removed, look at the locking pins and retract them completely by rotating the key (you can actually see a metal stop that moves). Now, put the cap back on the tank, and twist the cap clockwise (not the key) until you feel a positive stop (should sound like metal hitting metal), then rotate the key clockwise aprox 90 degrees until it stops turning. If the cap isn't fully seated or rotated far enough then the locking pins on the cap won't fully extend which means the key won't release from the cap.
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Old July 5th, 2015, 09:18 PM   #3
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After several fill ups, I thought my key felt a bit "sticky" when pulling it out of the gas cap. I put a tiny drop of MPT Twelve moly lube into the key hole and the key slides into and out of the lock with ease ever since. No comments about K-Y Jelly or any other quality lubricants, please!
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Old July 5th, 2015, 10:36 PM   #4
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Originally Posted by BelloStrada View Post
No comments about K-Y Jelly or any other quality lubricants, please!
How about using condoms on my rifle to keep water out of the barrell then?
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Old July 5th, 2015, 11:19 PM   #5
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How about using condoms on my rifle to keep water out of the barrell then?
is that to stop you shooting your load ?
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Old July 5th, 2015, 11:44 PM   #6
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is that to stop you shooting your load ?
No.....have been shooting blanks for years 😂
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Old July 6th, 2015, 06:46 AM   #7
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I think soap from washing builds up in the channel and makes it sticky. I used to leave my key in the seat release lock to keep my kids from turning the ignition. Thought it was a good place to leave it when washing. Eventually, the key mechanism got so gummy I had to run a lot of gun lube through it to free up.
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Old July 6th, 2015, 07:43 AM   #8
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The lid has 2 symmetrical tangs so it can go on in 2 orientations. One will result in your problem. take off the lid - rotate 180 and try the other orientation. This happened to me and I was puzzled for a little while.
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Old July 6th, 2015, 08:56 AM   #9
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first time i got the bike for a test drive, the guy told me to refill it. i spend 10 min with the same problem until i finally manage to reléase the key from the cap..

it has to be perfectly turn to the máximum to be able te reléase the key
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Old July 6th, 2015, 03:18 PM   #10
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Thanks to everyone who replied regarding the ignition key stuck in the gas cap. I'll try the suggested remedies and also get some of the MTP Moly lube (not familiar with that product) for future use.
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