@smiller871

Thank you for your simple helpful video. 
I spent 5 minutes messing around and couldn't get anything done.
I watched your one and a half minute video and baboom work like a charm.
Thank you so much for taking the time to post

@MikePonsAmerica1st

Thank Bruno. I have a 2008 KLR and was frustrated until your video. I hope life is treating you well.

@oneblackdogrides

After some (more) neglect mine jammed completely - after flushing & soaking in Inox (like wd40) I hit it with a hammer and broke it (a bit), but at least it eventually opened. The problem was not the key barrel, but rather the mechanism that drove the latch. The rotating aluminium bits had jammed. After cleaning & lubing it's now time to try and put it back together for another 10 years of fun.
Thanks for showing it's not just me!

@akonitony2

I found tilting the key had zero effect, but pushing down on the lid while turning the key ... was the key to unlocking it easily every time.

@soundzrinmygarden3833

Push down on the fuel cap with your thumb, then turn the key. It takes the sprung pressure/resistance away and the key will turn easily.

@Giovannie456

Great video especially for beginners like myself. Thank you

@MichaelGustavsonArchitect

Solution:   Open cap with key, then lubricate the big moving latch that goes in and out (on the tank side of the cap).  lubricate this "latch" as you turn the key open and closed several times.  You will notice that the key begins to work perfectly smooth and easy.  It's the gunk in the main latch on the cap (which is inside the tank when cap is closed) that is causing the problem.  It has nothing to do with the key mechanism, it's the latch attached internally to the key mechanism.

@FreedomFishing

The latch under the cap might just need some cleaning. Mine was gummed up from sitting and the latch didnt want to retract towards the center.

@a.c.e.7568

I bought my 2002 KLR 650 new and it has been parked since 2003, but indoors in a dry environment so this is not a corrosion issue or whatever. Well it is good to know that the ignition key is used because I thought it might have used a different key but my key only turns 45 degrees and not 90 degrees as shown in your video. And yes, I did push down on the gas cap. How can something like this not work after a piddly 6800 miles? Hell the gas cap key works on my much older 1990 BMW GS. Differences in quality, I guess. Rant over!

@DanteFox

My copy will only unlock my gas cap if I put it in one way. Its a case of. "The copy isn't as good as the factory cut"

@hmobb7838

I’m scared I just lost my only key and now about to make a copy from scratch ... hopefully my bike isn’t stubborn

@nikospapadopoulos555

this photobucket shows the assembly :
http://s73.photobucket.com/user/buddyboy16/library/KLR%20650%20Fuel%20Cap%20Assembly?sort=6&page=2

@WmLatin

I'm convinced it's a pretty stupid, cheap design. I have a LUN topbox and the key to it turns the gas cap lock just about as far as the ignition key did, and since it's short - the 'right' size- I thought that IT was the right key! Anyway, I got mine working eventually and will try to keep it lubed... I'd rather just have a simple non-locking cap as it's not likely I'll be parked where anyone would mess with the fuel anyway.