EV gas cap key won’t turn

[Gusable]

I don’t remember any issues 2 years ago with my gas cap not unlocking but today it won’t turn. The key that is.  Should be ignition key right? I put some kroil in there. We’ll see what happens.  The seller only gave me one key. He claims it worked for him   Bike did get quite wet during cross country transport.  Maybe a locksmith....

[oldbike54]

 Yep , same key . Try moving the key up and down gently while turning it .

 Dusty

[Gusable]

The kroil worked!!!! Now to check the moat.....

[pehayes]

Try pushing in on the entire cap while you turn the key.  There was a common issue with the modern fuel expanding one of the plastic components in the cap lock system.  That part can be removed and shaved or sanded down to work better.  MG Cycle sells a replacement cap that has the notorious plastic piece replaced with metal so it won't happen again.  Possible to remove your existing lock and install it into the replacement cap so you still only use one key.

http://www.mgcycle.com/index.php?main_page=product_info&cPath=286&products_id=2254

You might search for old threads on this board reporting about the issue and showing pictures of the repair.

Patrick Hayes
Fremont CA

[LowRyter]

take the cap apart and take a knife and grind of some of the plastic.  There's a thread here with a description, maybe 10 years old.  Someone might remember the particulars.  I had to do it to my EV's cap.

[pehayes]

Found this.  Pics and all.

http://motoguzzimaintenance.wikifoundry.com/page/Moto+Guzzi+California+Fuel+Cap

Patrick Hayes
Fremont CA

[Gusable]

I’m in my house slippers working at midnight ( we all do?) lol.  The o ring was torn. I’ll get one at work tomorrow. The plastic part with the tabs “ looks” ok.   Kroil bath from the topside is soaking the drain as we speak. The level did drop “slightly”😃

[Gusable]

Y’all are fantastic by the way 🙏🙏🙏

[twhitaker]

Steve Brenton (swbrenton on this board) made/makes a replacement for the lock cylinder. When I last checked it was $75

[marcmorrison]

I have discovered that when locking the gas cap, if you will turn the key clockwise ONLY far enough that you can remove the key from the cap, then it doesn't bind up the "lock ears" when removing the gas cap next time around.  When locking the gas cap, it's not necessary to turn the key with gorilla force all the way clockwise in order to secure the cap.  Try it!!

[s1120]

Found this.  Pics and all.

http://motoguzzimaintenance.wikifoundry.com/page/Moto+Guzzi+California+Fuel+Cap

Patrick Hayes
Fremont CA

That was the first repair I did to my new to me Stone. Easy fix and works slick now! 

[Zoom Zoom]

Gusable, the trouble you are having is due to the plastic part inside the cap swelling up. It was only after several sessions with mine over a few years that it seemed to no longer be an issue.

Set the cap on the table upside down.
Press down on the middle part and remove the pin going through it.
Lift the metal piece and spring off.
You will see a green or gray plastic piece. Lift it off.
Now, the surface of it that sticks is not the surface that would sit against the table. It is the inside vertical surface that fits over the metal part below. (From this observation point.)

At rallies, I have used a pocket knife to remove some material from the plastic piece until it moves easily. At home, I used a Dremel tool with a small milling bit. You don't need to remove a lot, just do a little and test fit it. You will know when it is enough.

Note that the plastic part that would touch the table has a couple raised bumps that are what you feel when you turn the key to open the cap. Again, this is NOT the surface that needs attention. Once it turns smoothly, reassemble and you are good to go.

Part of the trouble is that petroleum products cause it to swell so lubricating it ends up being counter productive. Later caps had a metal piece from the factory. I never worried about it since the fix was so simple and only takes a few minutes.

John Henry

[Zoom Zoom]

Oh, and personally, I prefer working the inside of the plastic piece rather than the surface of the metal part as described in a link on a previous reply.

John Henry

[Dean Rose]

Steve Brenton (swbrenton on this board) made/makes a replacement for the lock cylinder. When I last checked it was $75

Put one of those on my EV works great.

[guzzisteve]

I cut & polished the metal after issue came back. 2nd time cut plastic & metal, working fine for 12yrs. You can get an all metal version for $80.

[Gusable]

got Her all fixed! Thx again