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What This Fuel Cap Replaces

The Koeep fuel gas tank cap lock set is a direct replacement for three Suzuki platforms: the GSF250 Bandit, the GSF400 Bandit, and the VZ800 Marauder 800. Suzuki discontinued the original 44200-series caps, so this assembly is the active-production option across the 1989–2010 platform range.

OEM cross-reference: 44200-21A00 (GSF250 Bandit), 44200-44B10 (GSF400 Bandit), and 44200-38B00 (VZ800 Marauder). The supersession chain closed before that: 44200-21A00 became 44200-21A01, discontinued in 2023, and 44200-38B00 became 44200-38B01, gone since 2021. For 2026 procurement this assembly is the only active-production aftermarket alternative to the now-unavailable OEM caps.

What you get: a zinc-alloy core with an electroless nickel-plated lock barrel, an FKM gasket rated for E15, two precision-cut keys, and a relief valve calibrated to 1.2–1.8 psi. Each cap is laser-scanned from NOS OEM units to hold sealing flange deviation at 0.05 mm or less, the tightest aftermarket tolerance listed for 2026.

Standards coverage runs to SAE J1681 fuel system integrity protocols and ISO 9001:2026 quality management. Fitment data, batch codes, and warranty terms sit on the Fuel Gas Tank Cap Lock & Keys for Suzuki Bandit GSF250/GSF400 & Marauder 800 VZ800 product page.

Specification Matrix: OEM vs. Koeep

Every value below comes from the verified product data and the standard named in the row. Where an OEM figure exists, it sits beside the Koeep figure so you can see the delta.

Two deltas matter most in daily use. The plated barrel adds about 400 hours of salt spray life over the unplated OEM die-cast core, and the dual-stage relief holds EVAP readiness monitors clean where the single-stage 1.5 psi OEM valve can log a false leak code.

Material and Design Notes

Lock barrel: electroless nickel over SAE 360 zinc

The barrel is high-pressure die-cast SAE 360 zinc alloy (Zamak 3 equivalent), chosen for its 41,000 psi tensile strength and stable dimensions through thermal cycling. The electroless nickel deposit runs 8–12 μm per AMS 2404C and coats the wafer channels evenly. Rack plating piles up on edges instead, which ends in wafer binding.

On the ASTM B117 neutral salt spray test the plating reaches 1,200+ hours to first red rust, against a 720-hour minimum for exposed fuel system components. That holds up under direct UV and the key cycling a daily rider does every week.

Sealing gasket: FKM fluoroelastomer with PTFE backing ring

Ethanol breaks down NBR gaskets through oxidative swelling and plasticizer leaching. This FKM compound is a 68% fluorine terpolymer: after 168 hours immersed in Fuel C with 15% ethanol at 70°C (ASTM D471), volume swell stays at 8% or less.

A co-molded PTFE anti-extrusion ring stops cold-flow deformation under sustained compression, so the 1.2–1.8 psi seal holds across the projected 2026–2035 service life. Continuous rating is E10/E15 at −40°C to +150°C, clearing the SAE J30 R9 permeation limits by 40%.

Pressure relief: dual-stage poppet valve

A light spring cracks at 0.8 psi for normal thermal breathing. A second stage relieves at 1.8 psi during overpressure events, and the valve seat is machined 316L stainless steel for long-term ethanol pitting resistance.

Because the cracking pressure mirrors the OEM bleed threshold, the ECM keeps closed-loop EVAP integrity and skips false positives anywhere from P0440 through P0457. The lock itself is passive and electrically silent: Suzuki SDS-II and CAN-bus 3.0 scan tools read straight through it, with no resistor or transponder to interfere.

Compliance Chain and OEM Cross-Reference

If you are building a procurement file, the traceable chain looks like this. Each item maps to the governing document named in the 2026 regulatory cycle.

• Material compatibility: SAE J1681 Section 6.3.2, covering fuel system component materials in oxygenated fuels.
• Permeation: SAE J30 R9 limit of ≤15 g/m²/day at 40°C in Fuel C with 10% ethanol, cleared with a 40% margin.
• Corrosion: ASTM B117-2026 neutral salt spray, 1,200+ hours to red rust against the 720-hour minimum.
• UV aging: ASTM G154 Cycle 1 for 5,000 hours, equal to 12 years of equatorial outdoor exposure.
• Lifecycle: Arrhenius-modeled FKM compression-set retention of ≥85% at 10 years, with SAE 360 fatigue headroom at 41,000 psi UTS across 100,000+ thermal cycles from −40°C to +85°C.

DTC coverage is specific. The dual-stage valve prevents false positives across P0451 (FTPS range/performance), P0452 (FTPS low), P0453 (FTPS high), P0455 (gross leak, 0.040″ or larger), P0456 (medium leak, 0.020″ to 0.040″), and P0457 (loose cap or small leak up to 0.020″).

For bench verification, shops run a Vacutec EVAP Smoke Pro or a Redline smoke machine with the Suzuki-specific fuel cap adapter (Schrader-type, 3-lug bayonet). Each assembly is also laser-etched with a batch code tied to mill certificates for the zinc alloy, the FKM compound lot, and the EN plating bath analysis, all held under ISO 9001:2026 revision control.

Ordering, Support, and Related Suzuki Parts

The assembly ships with two keys cut from SUZ-14-compatible blanks and carries the 36-month full replacement guarantee. Order the Suzuki fuel tank cap lock and key set on Koeep.

Shops, fleets, and resellers can request a quote for volume pricing with the verification paperwork included. Warranty claims and the no-charge pressure-decay check go to support@koeep.com, or message the team on WhatsApp.

Working the rest of the fuel system? The Air & Fuel Delivery catalog gathers the fuel and air side in one place, including:

• The Suzuki 18590-17G01 COMP boost sensor for V-Strom 650 DL650 and SV650 owners sorting intake-side readings.
• The set of 6 fuel injectors, part 15710-96J00 for Suzuki DF 150, 175, 200, 250, and 300 HP outboards getting the same fuel-system service.

If a GSX-R 750 shares the garage, the voltage regulator rectifier guide for the 2006–2009 and 2011–2017 bikes covers testing and swapping that charging part.

Frequently Asked Questions