Gday Everyone I came across this forum after acquiring a sweet little 1994 ZXR250 from a work friend that has been sitting unused for about 3.5 years. I have no experience in restoring 4 stroke road bikes and have a dirt bike background. I'm looking forward to learning and the process in getting this little gem mobile again. First challenge is opening the siezed fuel cap so I can inspect the tank after I give it a good wash. Photos are of the good side, RHS has some fairing damage. Cheers Adamn
Looks is great nick mate , I get plenty of Bikes in with seized caps , I usually spray some wd40 down the lock and around it , let it sit for 20 mins then slowly and gently work the lock open , just little flicks each way and the lock will generally loosen up , don’t force it otherwise the key will snap mid your key is bent or in a bad way , go and get a new one cut before trying this
Yep, very conscious of breaking the key ! I'm fortunate that the bike has 2 keys, 1 Kawi and an aftermarket. I've soaked the barrell in Inox and a rust removal spray ... still doesn't want to rotate. The fuel cap is bulging up so I think it will be toast. I'm thinking I may need to drill some small holes on the key barrel so I can get circlip pliers on it to get some purchase and turn it.
Downward pressure on the cap to reduce tension on the latch, maybe a few taps with a rubber mallet to help loosen the corrosion. Push down and twist gently back and forth with the key after that. It will come eventually. If you have no success get a professional to do it, and if that doesn't work they should be able to remove the cap without damaging the tank.
