Help - KDX Gas cap problem

[XRDadKDXBeni]

Our 220, purchased new in July, has about 100 miles on it - the gas cap has split around the circumference almost half-way around. The limited warranty expired on 9/25 and the dealer is balking at free replacement. In my experience (40+ years) I have never seen a gas cap split like this on any make or model of bike. Is this a common problem with this particular gascap or with kawasaki plastic gascaps in general? Has anyone had a similar problem and/or has anyone had any success in having kawasaki replace the cap even though the warranty period has expired?

 

[KiDX]

I've had one crack on my 94. It was probablly due to it being constantly over-tightened. They cost less than $20 to replace, so don't worry about it.

 

[DANIEL JOSEPH]

Correct, they crack if over tightened. Make sure you don't throw out the rubber seal in the cap, you'll need it for the new one.
When you get a new one don't crank down on it . It only needs to be snug the rubber ring seals the fill opening.

 

[kx_693]

dont even bother with the big and bulky stock kdx cap, buy a kx cap they are smaller and ur not going to end up bing sore after hitting yourself on it. i run a kx cap on my kdx's, i race the gncc's and local ama races.

 

[DANIEL JOSEPH]

I did the same thing. The late model KX caps fit.

 

[ZKDX]

my 87 kdx cap was split all the way around...i purchased one from dennis kirk...when i got it, it wouldn't fit, even though the major, minor and pitch diameters where an exact match, after looking closer my tank threads had a bit of a worn flat on them, so i took out my pocket knife to the new cap, cut about .05 off the threads...fits perfect!

 

[XRDadKDXBeni]

thanks for the info guys - i'm not buying the over tightened angle - this bike is three months old and the gas cap should not split even if it is over tightened a bit. None of our other dirt bikes split a cap, my weedeater doesn't, my mower doesn/t my blower doesn't - I think the cap is manufactured with too thin a side wall and should be replaced by Kawasaki. Yes, I realize its less than $20 dollars; its more the principle of the issue - quality is quality and this cap is not quality if it splits when you use it for its intended purpose....and I don't think we are "over-tightening" it....we are simply tightening it. I think I gonna call Kawasaki and tell them Honda would replace it. Thanks again for you input. XRDad

 

[CMcCarthy]

Mine split on my '94 too, and I don't overtighten mine.

 

[Michelle]

I can't believe your dealer. As for telling Kawasaki that Honda would replace it, from what I've heard & seen, Kawasaki is absolutely brilliant with their replacement of stuff after the warranty's run out - gas tanks for 2-3 year old bikes? Would Honda still replace something then? Somehow I doubt it.
It's a pita that you feel you need to contact Kawasaki direct - dealers get a 1800 number to phone for warranty claims & a lot seem more than happy to phone it.
Let me know how you get on, because I honestly can't believe that Kwakka wouldn't replace it whether it's because you overtightened it or not. Believe me, I've heard of warranty claims a lot worse than yours that they've honored even though the bike's have been 1yr or more old.
Michelle

 

[Matt90GT]

my 94 250's cap did the same thing. $8 later and it was replaced

 

[Mrobbins]

Thanks for the cap tips. Just got a 97 KDX220 two week ago and I was getting splashed with gas (when full) with the cap on pretty tight.
Now I now that 1) you should not need to crank on the cap, 2) the KX cap is a smaller replacement. # 2 is key cause I crushed the family jewels on the KDX gas cap during a first ride crash.

Also searched this forum to find out:
1. Expected fuel milage
2 Performance effect of the Fatty pipe and Power Core that came on the bike
3. Rear shock sag setup
4. What computer to buy (TrailTech) to replace the missing Odo

I Love this place!! :worship:

Matt

 

[XRDadKDXBeni]

Happy ending! The dealer (owner) walked over to a 2003 KX and gave me the gas cap...works and looks nice on the KDX. It was the service manager who was doing the replacement balking.