My ignition key suddenly will not open my gas cap. The key goes into the lock easy and will turn about an 1/8th of a turn, but then it stops and will not turn far enough to unlock the cap. I tried both keys, same issue. I've sprayed lub down into the key hole several times, tapped on the cap with a rubber mallet, no luck. I'm in a jamb, can not put gas in the bike. Has this happened to anybody out there and what can I do to get the blasted key to turn all the way and unlock the cap.
This is a common failure of old lock cylinders. I have had luck by wiggling the key in and out slightly while gently turning it. If the pins are still in place and can move to the shear point, this will work. Did you turn the key while tapping with a mallet? This is called bumping the lock. Also a good method if you can get a good jolt to the cylinder. Once it is open, remove the cap and get the cylinder fixed or replaced. If the cylinder is still good most locksmiths can rebuild it good as new.
Try pushing down on the cap with your thumb above the key while you turn it. That's what I have to do to get the cap on my '89 to open and close.
Make sure you do lube the latch once you do get it open. Mine was a little sticky and had to push it down quite hard. Now, not so much. The only thing worse than a stuck key is a stuck half key.
I had this issue on my 1100. Unfortunately it wasn't the key cylinder problem, one of the retaining pins got broken inside the mechanism and wouldn't unlock. My repair guy managed to brake the pin without any damage to cap or the tank and then I just did the cheap cap fix from the forum.
Thanks for all the suggestions brothers, but unfortunately, I've tried them all. I just don't know what to do at this point. I hate to have to buy a new tank and gas cap assembly and lock - big bucks?
A new tank and gas cap assembly? Yeah, they're right next to the new fairings and front fenders...
We wish it were that easy, at any price. Sorry, but new is No Longer Available. If you really can't get the cap open, you are looking at something used. Ebay is a good place to start...
Bill
Is your bike a 1200 with the aviation style filler?
If so, and all of the above hasn't worked, the drilling out the key mechanism is an option. New fillers are cheap and readily avaliable.
If it is an 1100, then may go have mercy on your soul if you drill it out. Carnivorus hens with saber teeth are easier to find.
Mark
If it is 1100 you can break the pins and repair the cap easily like I said earlier.
Its a 93 1200. Do you get a locksmith to drill it out? I've never done that before. Where do you get a new inner lock from?
I would check with a locksmith for the drilling. I would also caution anyone drilling into a fuel tank that may have fuel vapor still inside. An empty tank full of fuel vapor and a spark from the drill bit would not have a good experience. Add to that with the cap stuck on, makes it harder to flush out any fuel or fuel vapor. I am sure there is a way, this must have already been done with our bikes as old as they are.
Quote from: retcol on September 26, 2017, 05:40:57 PM
Its a 93 1200. Do you get a locksmith to drill it out? I've never done that before. Where do you get a new inner lock from?
Then don't worry too much for the cap since you can buy it and find it without problems if the current one gets destroyed.
Quote from: FJmonkey on September 26, 2017, 06:22:58 PMI would check with a locksmith for the drilling. I would also caution anyone drilling into a fuel tank that may have fuel vapor still inside. An empty tank full of fuel vapor and a spark from the drill bit would not have a good experience. Add to that with the cap stuck on, makes it harder to flush out any fuel or fuel vapor. I am sure there is a way, this must have already been done with our bikes as old as they are.
Retcol,
Work carefully, outdoors of course, and avoid making sparks. I would suggest removing the tank from the bike, and removing the petcock to drain the fuel from the tank. Then fill the tank with water, remembering that gasoline floats, so keep the opening upward and let the flowing water flush out any remaining gasoline. Then drain the water from the tank. Leave the petcock off, until you get the gas cap fixed.
Good luck!
THANKS EVERYONE! :good2:
Remove the seven screws around the fuel cap, pull the assembly from the tank. Then work on freeing the lock tabs from the bottom. Everyone trying to help had assumed you had 84 or 85 tank.
Chris
There are seven screws but only three are used to hold the cap.
Chris
Chris, I tried that, but after removing the seven screws, the assembly would not budge. I looked at a YouTube video of a man changing out his assembly and I saw that there is yet another screw under the gas cap that holds the assembly in. Of course, if you can't open the gas cap like I can't, then there is no way to get to that last screw under the cap holding it all in place.
Are you planing to drill out the lock cylinder or the cap to get access to the hidden cap screw?
I really don't know, I've never done either one. Maybe I'll carry the tank to a locksmith and see what he can do.
If you are still stuck on this problem before you drill out the lock put the key in the lock and wedge a screwdriver in the slot by the key an use the screwdriver to put more torque on the lock to see if you can get it to pop. I use a flat head that allows me to put an adjustable wrench on the screwdriver for more leverage. I push down on the screwdriver with one hand while working the wrench back and forth and usually can get the lock to go. Just make sure the key is seated in the lock fully.
Most of the time it's not the lock that is the culprit it's usually the oxidation on the tab that latches the lid. Hope this helps you out or if not can help someone else that has had this issue looking for an easy fix.
Thanks squidley, I'll givbe thid a go tonight!
As our member retcol is searching for a way to get his gas cap open an ADV member had a suggestion. Remove the tank from bike and remove the gas gauge. This would allow access to the back side for lubrication. It may also allow access to the two tabs to be manually moved after letting them sit in oil a few days. What do you think?
Dave
Good idea Dave....I wonder if it would work?
There is a interior filler tube at neck of the opening which may make access to the underside of the gas cap a bit a dodgy.
The 93 I purchased last year has the tank off. Removing the gauge on the bottom front right side one of the tabs is clearly visible and could be GENTLY tapped with a long screwdriver. The other tab is not visible. Just looking at them you could tell if they were corroded. Both are clear for some oil.
Dave
Thanks amigo! Good to know :good2:
If here is enough fuel left what about riding it around to a locksmith?
Quote from: Troyskie on January 11, 2018, 03:19:43 PM
If here is enough fuel left what about riding it around to a locksmith?
He has the right key and it will partially turn the lock. The problem is the mechanism that turns the two locking tabs. I suspect the locking tabs and/or mechanism is corroded.
Dave
He has the right key and it will partially turn the lock. The problem is the mechanism that turns the two locking tabs. I suspect the locking tabs and/or mechanism is corroded.
Dave
[/quote]
Very true Dave, but locksmiths have solved some mechanism issues related to locks for me in the past (jammed gun cabinet mechanism on the three way thingy). Admittedly not this specific fuel cap issue, but as the fuel cap is part of the lock system they'd have the tools with best chance of being able to make it open.