It's a known issue... ever hear your tank venting through the keyhole in the summer when the fuel heats up? It dries out any lubricant on the tumblers and then the condensation creates oxidation that caused them to seize up. I just put some graphite lube in the key hole a couple of times a year and work it in with the key. I haven't had an issue since the first time it locked up.

Mine was getting hard to put the key into this summer so I just oiled it and the problem is gone. Pretty easy thing to deal with really, works real slick now.

another trick ive picked up, only if you must! is take something strong such as like a nail or something and stick it under where the release is and then pull up and it will pop it open, it will peel paint though doing this

To keep it from happening, occasionally blast the lock with a graphite lock Lube. Do it to your ignition as well.



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crc 556 in the green can will free it up even if stuck for years. just spray and wait 24 hours. works on seized rusted cylinder bores too.

I use a PTFE lubricant every few months see link:
Master LockŪ - Care and Service of Master Lock Padlocks - Master LockŪ

Just put a squirt of oil in there and you will be fine. I used a good squirt of chainsaw bar oil and have not had any problems, just smooth, good working lock on the gas cap.

Keep in mind, if you live in a cold climate area and you ride in the winter most canned oil will freeze so be sure to check the freeze point of the oil. Although this really shouldn't be a problem for 99% of riders.

oh man i know all about this story. remind me of when i was about 19 i had a 76 kz900 one morning i was getting ready to leave for work and was already running late decided i better check to see how much gas i have before i leave. put the key in and wouldnt turn i tried several times. by the end of the third try i lost my temper and punched the tank about 3 times(huge dent) right on top of tank and still didnt open. so sat there for a min. to calm down then sprayed wd40 on it and opened right up.to this day i still kick myself for that one (stupid teenagers and there tempers) lol.

I ride my bikes in all weathers, I always go through all the locks first with a penetrating oil spray like WD40 to ensure they are clean, then I pack them full of underwater grease, I do exactly the same with all the block connectors in the wiring harness, which helps prevent any potential corrosion build up, most boat shops should sell underwater grease.

Interesting. I have a story of my own and I think something else is going on here. My buddy and I both have the identical bike ("11 N1K) 8 months old. My bike has had zero problems with the locks. My buddy on the other hand has been through two (2) sets of locks in 8 months. Bike is garage kept - very low miles - and there is nothing in the garage that would foster corrosion. When I tell you these locks are corroded, I mean they look like they have been at the bottom of the ocean for the last 12 months. NO amount of spray would help them. Just a big, white/green corroded mess! Dealer had to replace all the locks both times (under warranty). I think there might be a problem with electrolysis. Thinking maybe there is a ground wire problem or something along those lines causing the problem - dunno. Anybody have any thoughts on that theory?

Easy way to test for potential electrolysis... start bike, put the negative probe from a multimeter on the negative terminal on batter, put red terminal to the lock cylinder. If you see anything other than 0V, you've got a problem... It doesn't rule it out entirely, but it should be about 98% accurate...

Originally Posted by Black Sheep

It's a known issue... ever hear your tank venting through the keyhole in the summer when the fuel heats up? It dries out any lubricant on the tumblers and then the condensation creates oxidation that caused them to seize up. I just put some graphite lube in the key hole a couple of times a year and work it in with the key. I haven't had an issue since the first time it locked up.

Interesting, never heard it put like this. Makes sense though. I bought my Ninja 1000 new and had problems with the tank from the get-go. After a year of owning I bent both supplied keys. I ended up buying an aftermarket Vortex V3 gas cap last month and will never look back. Too many issues with stock Kawi gas caps; had a new Ninja 250R with the same problem. Best of luck OP.