clean/lube your gas cap lock tabs

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by xcflyn, Feb 10, 2012.

  1. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,166
    Location:
    Rocky Mountains
    Had a interesting experience with my left side cap lock cover a few weeks back when I went to fill it up, could not get the thing to flip up. I didnt want to force it and only needed a gallon to make it home so I just filled the right. Once home I got out my feeler gauges and worked the little ball and got it open. Then it wouldnt shut. This was my method- do what ever trips your trigger or do nothing :patch But I blew out the area with my trust bottle of compressed air for my computer, then put tiny drop of 3 in 1 on each ball and worked it with the .003 feeler gauge. Did both sides right away and have not had a problem since. Im sure someone will say use WD40 or teflon or what ever, BUT- this is what worked for me and I am riding in dusty sandy conditions nearly every day. The 3 in 1 has not collected any grime to the area. I used the tip of a paper clip to apply it, I didnt trust my smooth squeeze of the can to drip one tiny drop: im sure it would have been way too much.
    Not that this is something to re-write the manual for. But it sure could have been a hassle to deal with if I really needed to fill that side up. Pics show the places where the little balls are. Its just a simple ball (plunger) and detent system.

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    #1
  2. Geek

    Geek oot & aboot

    Joined:
    Jun 8, 2003
    Oddometer:
    33,296
    Location:
    8000ft.
    Another tip... open the cap and remove the "anti theft screw".

    That way if you ever lose your key on the road (or break your key off in the lock) you can easily unscrew/remove the cap to put fuel in the tank. :deal
    #2
  3. Chuckracer

    Chuckracer Jerkus Maximus

    Joined:
    Aug 26, 2007
    Oddometer:
    9,190
    Location:
    Lowville, NY
    Is this in the HOW (yet)?
    #3
  4. plumbtired

    plumbtired plunging into the farkle

    Joined:
    Apr 13, 2008
    Oddometer:
    184
    Location:
    Slo Cal
    I see no mention of this issue to date. :huh
    #4
  5. Supahflid

    Supahflid Wheelieless

    Joined:
    May 29, 2008
    Oddometer:
    3,912
    Location:
    Here for reals.
    I had this exact trouble on the right side tank and it happened, of course, when I was filling up on a weekend trip. I just broke the cover off, fully expecting the dealer to replace it since it was a new bike and there was no way I was not filling up the tank over a stupid jammed dust cover.

    I talked the dealer in to giving me the replacement so I wouldn't have to leave the bike with them. He gave me the whole tank filler cap. It was super easy to replace and it was even keyed to my bike; at least I don't think all KTM keys fit all gas tanks. I use a little squirt of silicone spray to keep both covers lubed now.
    #5
  6. Masa

    Masa Been here awhile

    Joined:
    Sep 25, 2011
    Oddometer:
    303
    Location:
    F1nland
    #6
  7. Supahflid

    Supahflid Wheelieless

    Joined:
    May 29, 2008
    Oddometer:
    3,912
    Location:
    Here for reals.

    Yeah, I tried to be careful and not break the thing, but it was jammed pretty bad. After geeking with it for several minutes, I finally decided to just prize it up until it either flipped up or broke.
    #7
  8. Masa

    Masa Been here awhile

    Joined:
    Sep 25, 2011
    Oddometer:
    303
    Location:
    F1nland
    Same here.. But I had better luck.
    #8
  9. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
    Oddometer:
    2,631
    Location:
    Main Street, Shedd, Oregon
    I've seen this on a 2012 Adv R. It is due to a bad shaped casting on that 'flipper thing'. If you pull out your knife and poke the blade between the flipper and the ball it will open.

    ALSO, you can fix it in 2 minutes by carving the 'flipper thing's' ball catch. It is ramped a little too steep and only takes a couple of swipes with a knife to fix it.

    OR, you can get it replaced by KTM. But, the caps are not available at this time and they cost about $200. The new one may have the same problem too.
    #9
  10. drued

    drued Adventurer

    Joined:
    Mar 25, 2011
    Oddometer:
    71
    Location:
    Glen Ellen, Ca
    I had an '05 950 for 90,000 miles with no problem. I now have a '12 990 with 7,000 miles and this problem just came up. The dealer is taking care of it under warranty. The ball actually deformed the tab causing the lock up. Not a serious problem, but it is annoying.
    #10