KTM 990 ADV Fuel cap problem

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by BIGCOD, May 14, 2013.

  1. BIGCOD

    BIGCOD the desert ninja

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    Hi Guys,

    Has anyone had a problem with one of their fuel cap locks not working properly??

    My right hand side lock wont open and I have tried most things including taking it to a lock smith! Just wondering if anyone has had this before and what would be the best way to open the tank and replace the lock?

    Cheers, BIGCOD :freaky
    #1
  2. Iwantabikesobad

    Iwantabikesobad Long timer

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    Not sure how to get it open with a broken lock. When the filler lid is open, at the seven o clock position there is a allen head screw. Remove this screw.
    Then if the lock ever fails again you can simply unscrew the retaining screws on top of the filler lip and remove the entire cap/lid assembly. Handy in the middle of nowhere.
    I have seen a few people install complete aftermarket filler caps that screw in and do away with the locking mech, all together. Have seen them on e-bay.
    Let us know how you get the lock open
    #2
  3. BIGCOD

    BIGCOD the desert ninja

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    Yeah I thought of that but decided nah "i'll never need that!" lol. Now I wish I had undone that screw because when you need it its too late to unscrew it if you cant undo cap!!:wink:
    I can order a new cap from KTM in Austria($350) that will take 2 months too arrive!! I will give the lock smith one more try, he thinks a new key might open it??
    #3
  4. BykBoy

    BykBoy Meshuganeh

    Joined:
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    Reston, VA

    I have a problem with the key cover not flipping open. Had to file down a small notch on on the side and use a very thin pin to push the ball push pin into place every time I wanted to flip the cover open.

    No problem with the key and lock though.
    #4
  5. gefr

    gefr Life is a trip

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    I dropped a few drops of engine oil at the key, as it was inserted in the lock. As oil leaked in, I wiggled the key and it unjammed. Just needs some gentle touch.
    For the key cover, I jiggled it until it opened. Put some grease at the little securing ball and works great. It lasts for a couple of years.
    Simple solutions to simple problems.
    Cheers.
    #5
  6. MOTOSOTO

    MOTOSOTO Light Fuse and Get Away!

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    ...I, too, am suffering from the "right hand side key lock" problem...followed the 'drop some engine oil and wiggle it' and after a few nights after work 'wiggling' in garage...the key finally dropped 98% in. It won't turn since it's not completely 'in'...going to try my 'handy work' and then give the locksmith a call...ridiculous failure...and a constant reminder that the only adventures this bike's given me has been with mechanics' bills...and now a locksmith bill...Keeps Taking Money...
    #6
  7. gefr

    gefr Life is a trip

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    You do not fill up once a month? From now on you can oil the locks once a year. To help it unjam, you could also spray something thinner as WD40.
    For longer storage periods you can stuff the keyholes with grease.
    Cheers.
    #7
  8. MOTOSOTO

    MOTOSOTO Light Fuse and Get Away!

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    ...my bike gets used regularly-when it's not with the mechanic...and the fuel cap/keylocks get used quite a bit on those rides...problem solved in exchange of $85.00 and an hour with the locksmith...he said that the 'elements' were worn and one of them kept the key from sinking in 100%...all better now...considering taking out the bolts that secure that lid to -what looks like- the tank...in the event that keylock issue surfaces again/on the other tankside...
    #8
  9. BIGCOD

    BIGCOD the desert ninja

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    Just a quick update on the lock dilemmas! I tried hundreds of times to open it myself using inox (better than wd40) in the lock and pushing it, pulling it, holding cap down etc etc. The locksmith tried too and he cut new key which didn't make any difference except to my wallet lol.:huh

    I got my mechanic to drill the lock which he did perfectly and now I just use a screwdriver to open the cap lol :evil With all the dust and wear and tear from off roading he things some pins in the lock have failed. Im not going to get a factory one just yet ($350 and 2 month wait) as the screw driver works fine!
    I am looking to buy a 2nd hand cap if anyone has one available???

    Anyway moral of the story is.........UNDO THE LITTLE GRUB SCREW INSIDE THE FILLER CAP BEFORE THIS HAPPENS TO YOU.
    #9
    DirtyADV likes this.
  10. tsiou

    tsiou Ninja

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    Bump!

    Same problem here! Right-hand fuel cap lock stuck... Just noticed that in the gas station... I can't believe that there 's no way to remove the fuel cap (even after removing the whole tank) to get away with it! The key doesn't even get in; only ~20% of it. I sprayed it with WD40 and I'll see what happens as soon as I return home from work! F*cking rust!
    #10
  11. gefr

    gefr Life is a trip

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    #11
    keener likes this.
  12. Peanuts

    Peanuts Long timer

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    I have known people drill through the cap to undo the hidden allen screw, but study a good tank before you start!
    #12
  13. keener

    keener Speed changes you.

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    During a long trip Newfoundland couple of years ago I broke of the key inside the right tank cap. No one could take the broken part put. Took it to couple of lock smiths.

    I got home (each fill up took 20min) and took out the left side, marked the exact location of the last bolt under the cap and mirrored it to the right side.

    Drilled a 1/8" or a bit larger hole right above the last bolt on the right cap, sent an allen key down and voila the cap came off. I later covered the hole with gray epoxy.

    I could easily take the lock core out. On the side of it there was a slot to push the broken key out. Thoughtful design!

    The core of the lock can be replaced easily if needed. I'll see if I can find my photos and update this post.

    Here ya go
    [​IMG]

    [​IMG]

    Remove this oring
    [​IMG]

    Press this last pin to take the core out
    [​IMG]
    #13
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  14. FakeName

    FakeName Wile E Coyote SuperGenius

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    Thanks for posting this- if it's any consolation, that is.

    I just pulled both mine apart, cleaned, lubed, etc. They work much smoother now and will hopefully avert a future failure.
    #14
  15. Rharr

    Rharr Been here awhile

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    any reason to keep that hidden allen bolt installed? Looks like it's just a security feature and if you remove it then you can just unbolt the whole deal externally.
    #15
  16. DirtyADV

    DirtyADV Long timer

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    Just a security thing. Have removed them on both my Swedish bikes, might have to check the Phoenix 990 if it still has them ...and remove them. Have not checked my fathers 950 either so will do that also.

    We did try to break a key in the fuel cap on a KLR, Nail clippers are really good at grabbing things that hardly stick out:

    [​IMG]

    I try to bring a spare key after that ordeal since it was the only key, luckily we were in a Town big enough to have a locksmith but stole several hours locating it and they guy that could handle double sided keys had to be called in and it was a bit hard to line the 2 parts up in the machine good enough but we got it working and had a spare cut also.

    /Johan
    #16
  17. Central Cali Rider

    Central Cali Rider Love the journey and destination...

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    Since my fuel cap snapped off years ago due to struggling with a California massive fuel nozzle, I went to these. No more fumbling for the keys..

    It is garaged through..


    [​IMG]
    #17
  18. RedRupert

    RedRupert Brit in the Soviet Union

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    Once you've got the core out, can't you or your locksmith replace the core with another (with pins to suit your key)?
    #18
  19. jlw

    jlw Adventurer

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    Niagara, Ontario
    Link?
    #19
  20. Peanuts

    Peanuts Long timer

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    You are not alone in not knowing that the caps are left and right handed.
    #20
    keener likes this.