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Gas Cap won't unlock

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Gas Cap won't unlock

Postby Nifty_Fifty » 04 Apr 2014 04:42

Hi All,
Im new here and hope someone can offer some advice.

I just picked up an '05 Madass.

I have the correct key, and it works fine in the ignition and steering lock, but I can't seem to get the gas cap off.
Is there a thread or post on removing a locked on cap, or has anyone else managed to resolve this issue?

Thanks,
Wayne.

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This is the way mine works

Postby bouldergramp » 04 Apr 2014 10:43

This is the page from my manual.
You do not have the required permissions to view the files attached to this post.

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Re: Gas Cap won't unlock

Postby Nifty_Fifty » 04 Apr 2014 15:55

Thanks for the instructions.
I have tried this method with no luck.
Based on the instruction images, the cap has been fitted upside down. This may have something to do with it.

The lock cover won't rotate freely with the key in. the lock must be broken

Has anyone managed to remove a fuel cap without unlocking it, like if you were to loose the key?

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Re: Gas Cap won't unlock

Postby Nifty_Fifty » 05 Apr 2014 02:01

Ok, so it goes like this.....

The bike has been poorly stored since 2012, and left in the weather.
I had to drill out the lock and force the gas cap to get it off.
I managed to get the large flange off and was left with the bayonet piece that goes into the tank neck.
This piece had corroded so badly inside the neck, it was too big to rotate and come out. In my efforts to remove it, unfortunately it fell into the tank.
I will fish it out later with a wire hanger.

I found a universal plastic cap that fits ok for now.......

I also dismantled the carby, and found the main jet had been completely blocked with cottage cheese looking crud.
A quick clean with carboy cleaner and all was good.

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Re: Gas Cap won't unlock

Postby mymadassisbadass » 05 Apr 2014 11:32

I would first try spraying it with some penetrating oil, let it sit, and try turning it again. Sometimes the gas cap lock mechanism can rust up or corrode inside causing it to malfunction. If you try the penetrating oil and still can't get it off, your only option is to cut the gas cap off with a grinder (not easy or fun, and not particularly safe especially dealing with the fuel and sparks). I had a gas cap lock get stuck before after riding in the rain, and I had to cut it off and replace the cap. The upgraded gas caps are much better than the stock un-gasketed gas caps at keeping out dirt IMO.
2006 MA 50 W/141cc Lifan semi-auto engine & custom exhaust -- Old and Tired --
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