I think there is a thread about this. I know I read something about switching gas caps and have trouble getting the holes to align. Sorry I am not much help. This is an excuse to buy a keyless gas cap from rd.
I got it out, when I put it in the new cap it won't turn, I'm guessing I need a locksmith to cut the cap to suit my barrel+key. maybe someone with better expierence of locks can tell me what I'm looking at here:
Here's how to remove the barrel.
Step 1: remove the gas cap from the bike, then undo the 2 screws on the red section of the lock.
Set the rear half of the lock, the ring and springs aside and you should see this:
Step 2: Remove the rubber o-ring and you should see the first brass washer
Step 3: push down on one side of the brass washer until the other end pokes out and remove it, do the same for the brass washer underneath it
Step 4: you should be left with this, push the retaining pin back into the barrel and slide your barrel out
Cheers, I'll have another go tonight, i thought I had it in the same way as the old one but who knows.
I guess a lack of sufficient lubrication could also contribute? the barrel does actually rotate just not very much. maybe it's sticking or too tight or something.
I'm guessing the tank + cap are the 2012 parts sprayed with the colour and decals from 08? they wouldn't have old tanks sitting around I guess.
The lock barrel is the same on all the them. I'm sure of that. It is possible that there is something wrong with the release mechanism but I have gotten the bag locks in 180 out several times and it does what you are describing.
If I want to get a new metal cap for the top of the lock (because I bent the one on my gas cap) do you reckon I can just buy a new locking barrel that's meant to be used on triumph panniersor something? I can't find a part number for just the tank locking barrel or anything. I get why that would be though.
I've found Part number T2500693 for "Locking Barrel" but have no idea what bike or lock it is for.
Just thought I'd update this to let you know that it did indeed work, it still didn't turn but it was because the barrel needed to be lubed. the old one was full of graphite but the new one only had a fine layer of grease.