TOPIC:

Im having a problem to get the key to turn in the ignition on my project bike. It works fine in the fuel cap though. Should I continue drowning it in WD40 until it works or,are there 2 seperate keys for the fuel cap and for the ignition?

Do NOT use WD 40 in ignition, go to the hardware store & get a tube of powdered Graphite to put in ignition switch
Pete

Missing the point Pete.Whether its WD40 or powdered graphite, if Im trying with the wrong key,it aint going to work!

Gas cap & ignition should be keyed the same, & WD 40 can short your ignition

www.google.com/url?sa=t&rct=j&q=&esrc=s&...m=bv.119408272,d.cWw
Pete

The problem is likely in the ignition cylinder/key fit. As far as I know, the fuel caps on most kzs don't have any tumblers, so they're not really a 'lock' at all. Just a way to prevent very casual mischef.

So, your key not fitting the ignition is going to be the problem. Nothing to do with it working in the fuel cap. Look up Rob, a user here (rstnick) he is a locksmith, and makes keys for kzs.

As I recall, on at least some Kawasaki models, the ignition switch and the seat latch have a number that matches the number on the factory-provided key that operates them.

See the stickied topic, "Making a key by the code number" in the Electrical forum.

Good Fortune!

OK.Great.Thanks people. Now I know which direction I should be looking. I have the right key but the cylinder in the ignition is somehow stuck.
( It worked fine about 3 years ago when I stripped the bike. Its just been sitting in a box since). Ill have a go at finessing it.If that dosnt work,Ill look to a locksmith.

If you can get the numbers of the seat lock or the fork lock, there are locksmiths that can make a key by the #, also you can buy an ignition switch to match the #'s of your seat or fork lock, so you don't have to have separate keys if your ignition switch is just toast
but I would try the Graphite 1st, it's made for locks to lubricate the tumblers
Pete

Well,Ive been fiddeling with it and I got it to turn to the steering lock (twice in 20 mins. No more!). I pulled the bottom off it (the electrical part) to look for any kind of number. No number. Ill have to have a dig around for the seat lock,see if theres a number on that.
Im not worried about the fuel cap or the seat lock as Ill not be using them,I just need the one key for the ignition.The key itself does look pretty knackered with very rounded teeth,so the barrel itself could be fine and its the key thats worn out.
Ill play a bit more with it before I take it to a locksmith.
One thing to mention. I did grind a bit off the front of the casing to get it to fit into the new formation on the bike. Knowing my luck,thats where the number was stamped. DOH! I never noticed a number before but, then I never had the need to look for one.

I don't think the # was stamped in ign. switch, & on 81 & up I believe the # was stamped on the back of the seat lock which you would have to remove to see, I think martin csr knows more about where you can find the #'s, I'm sure he will chime in, , or maybe rstnick will,
Pete

I don't know that much about it, just the 650-csr. The 1000csr is probably the same or similar, though.
After determining the code, one source for replacement keys is eebbaayy: try searching the key number --- I did the other day & found a seller who cuts new keys using the code you provide. 2 Kawasaki Keys Code Cut Z5601 thru Z5650

1981 KZ650-CSR code location: ign switch, seat lock & helmet lock. Example code: Z5064.
I'm not 100% sure the seat lock code is noted correctly in the pic. doh.

You could try going to your local hardware store and have them make you a key for a couple bucks. It will be new and sharp. That might do it. It worked for me.
Steve