DL650 glee fuel cap frozen?

[himaro]

Recently I had to replace my ignition system (some idiot tried to steal the bike by forcing a screw driver into it... )
With this I got a new key and filler cap.
Today I went to fill up on fuel on my way into work to find that my key will no longer go fully into the filler cap to unlock it.
it's in the negative ^C's at the moment so it's bloody cold. Is this the freezing temps causing this or is there something more?

[mr_diver]

I used to have to defrost the ignition to start the bike, then get to work and have to defrost it again to remove the key.
I could at least turn the engine off.

[Rich:-)]

I'd give that lock a good flush out with WD and then put tape over it when parked to stop water pooling on it (even though the flap covers it).
I know there are mixed opinions on what to lube ignition barrels with, some say dry lube like teflon, others use nothing more than powdered pencil lead. I use silicone grease as I already have some for other jobs.

There is a bloke on another forum who has just had to spike his with a screwdriver (different bike but still Suzuki), his was stored in a garage. Maybe it's the cold weather or maybe it's bad design.
Bad design was blamed in this instance, it's a known issue for that bike (but not for Vstrom btw).

[himaro]

Just went out from the office to try again and it's still solid. it goes in about 5mm but it feels like the pins have seized.
Pretty worried right now as it's 17 miles to get home and I'm almost on fumes!
Don't have easy access to a hair dryer in the office funnily enough.
Bit odd that they would seize though, like I said, it's recently been fitted and the barrel is less than a month old. The main ignition barrel works fine.

[King Orry]

Try giving it mouth to mouth.. if it is just the cold a good few breaths into it should warm it through.
I’ve done this successfully on my shed padlock a few times.!
Just make sure your lips don’t get stuck.. riding home with your head glued to the tank may be ‘less than ideal’. ????

[hotbulb]

You could try heating the key with a lighter - perhaps a combination of a heated key and some WD40 will do the trick.

[King Orry]

Or take a cup of hot coffee out, sit it on the cap and let the heat radiate out.

[Brockett]

I hate to ask daft questions but have you ever used that key on that petrol cap?
I agree a bit of WD in there may help and then heat the key a bit ( not red hot).

[himaro]

Silly questions do have to be asked
I use the bike daily so yes, it's been refilled a dozen times or so since fitting.
I'll ask the facilities blokes if they have some WD40 around anywhere and see about transferring some heat into it.

[Rich:-)]

You could even try spraying screen de-icer in there if desperate, I'm guessing you work colleagues should have some of that... but I'd want to have lots of WD (and lots of rags) on hand to flush that out afterwards.

[BigAldo]

Remember too that it's not the 'lock' that freezes, it's the moisture inside the lock. When you get home, take the fuel cap inside and sit it on a radiator for a few hours to get the moisture to evaporate. Then a few drops of light oil to prevent moisture getting back in. Work the oil into the mechanism using the key.
I realise this doesn't help your immediate problem, but its something worth remembering.

[mr_diver]

I used de-icer spray then WD40.

[himaro]

I'm back in! 
Left the bike to bask in the sun and put some WD40 in the mechanism.
Something to be aware off in the future I guess.

I live in a flat with allocated parking so I can't really take the fuel cap inside.

[UK_Vstrom650]

Hot water poured over the cap may have sorted that out... but glad you're sorted

[Tintent115]

We used to pee on the locks of the work vehicles when they froze up...................

But that might not be the ideal solution if it's outside your office....

[mrp192]

I used to have problems with my Bandit ignition and fuel cap, similar looking setup, in the winter when left outside at work.
I got one of those small microwave heat up bean bags and zapped it short time before leaving and left it on top of the lock with some foil over it to try and direct the heat down.

[Freddyfruitbat]

Just make sure your lips don’t get stuck

Ohhh that takes me right back to an embarassing winter incident about 30 years ago...