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Old 02-10-2012, 05:45 PM   #1
xcflyn OP
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Joined: Mar 2010
Location: Rocky Mountains
Oddometer: 1,131
clean/lube your gas cap lock tabs

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 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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Old 02-10-2012, 05:47 PM   #2
Geek
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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.
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Old 02-10-2012, 06:01 PM   #3
Chuckracer
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Is this in the HOW (yet)?
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Old 02-10-2012, 08:46 PM   #4
plumbtired
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Not there yet.

Quote:
Originally Posted by Chuckracer View Post
Is this in the HOW (yet)?
I see no mention of this issue to date.
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Old 02-12-2012, 01:48 PM   #5
Supahflid
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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.
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Old 02-12-2012, 01:58 PM   #6
Masa
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I opened mine with force, greased them balls and it's been working just fine.

http://www.advrider.com/forums/showthread.php?t=735100
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Old 02-12-2012, 02:02 PM   #7
Supahflid
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Quote:
Originally Posted by Masa View Post
I opened mine with force, greased them balls and it's been working just fine.

http://www.advrider.com/forums/showthread.php?t=735100

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.
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Old 02-12-2012, 02:06 PM   #8
Masa
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Quote:
Originally Posted by Supahflid View Post
...I finally decided to just prize it up until it either flipped up or broke.
Same here.. But I had better luck.
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Old 11-13-2012, 10:49 PM   #9
Zuber
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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.
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Old 11-14-2012, 07:33 AM   #10
drued
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Location: Glen Ellen, Ca
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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.
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