Sorry about the avg quality photos, i only have a camera phone.
Step 1)
Go to bunnings buy 2.5mm or 3.32" drill bit. Get phillips head and get small allen key from toolkit under cowl on bike. Break out drill with variable speed. My bosch cordless did the job nicely.
Step 2)
Unscrew 6 allen bolts on tank with allen key. There is also 1 phillips screw on the inside lip of the tank. Do not drop this screw in the tank unless you want to go fishing with a magnet or remove and drain the tank.
Note Phillips screw:
Step 3)
Put rag over tank so crap doesn't get in there whilst your working on the cap. *important*
Step 4)
Unscrew 2 screws with phillips
Disassemble (note the order of the parts, you really can just remove it all in one go)
Note (in blue) the washer, this is will fly off if you dont remove it.
Step 5)
Remove the latch and spring from the latch piece and drill with 2.5mm drill bit. Drill very slow, you dont need to put much pressure on it the drill will makes its own thread through the metal.
Remove swarf with a pen or something.
Step 6)
Remove the 4 springs and drill the two holes show in the picture. Underneath there is a diaphram, so again drill very slowly, you'll fell when the bit breaks through. As soon as it does immediately reverse the drill and remove swarf. Someone said that if your ninja is still under warranty you can claim a new fuel cap but best not to trash it.
Step 7)
Put 4 springs back on and reassemble. To put latch back on it was easier to tip its on its side
Reassembled:
Step
put cap back on bike, 6 allen screws and 1 phillips. Again avoid dropping screws in tank for more pleasurable experience.
Step 9)
Go for a hoon, leave bike out in the sun for a while and hopefully your bike won't be a tea pot anymore.
Mines been outside and i went for a fair ride without any squealling...so far.
