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General Category => Maintenance => Topic started by: xtown_bikeboy on April 17, 2013, 01:45:54 PM

Title: Removing Gas Cap Assembly Without a Key
Post by: xtown_bikeboy on April 17, 2013, 01:45:54 PM
I picked up a spare tank I'd like to refurbish and repaint but the cap was closed and locked.  Anyone have experience with removing the cap (ok to wreck cap and lock I guess) without damaging the tank?
Thanks in advance for any help or suggestions.
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: rktmanfj on April 17, 2013, 01:53:10 PM

Assuming that it's not one of the early 1100 caps, there's a bolt in the middle of the assembly that is hidden by the cap.

Title: Re: Removing Gas Cap Assembly Without a Key
Post by: racerman_27410 on April 17, 2013, 04:00:16 PM
you can always just drill the lock.... like Randy said there is a bolt under the 86 and later model caps that there is no way to get to with the cap closed.


KOokaloo!
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: rktmanfj on April 17, 2013, 04:08:17 PM
Quote from: racerman_27410 on April 17, 2013, 04:00:16 PM
you can always just drill the lock.... like Randy said there is a bolt under the 86 and later model caps that there is no way to get to with the cap closed.


KOokaloo!

It's fresh in my mind because I just dealt with it last weekend... can't imagine why it didn't want to open.   :unknown:

(http://i643.photobucket.com/albums/uu159/rktmanfj/1990%20FJ1200%20project/20130414_130100_zpscf772471.jpg)
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Pat Conlon on April 17, 2013, 04:53:35 PM
Holy moly, what a mess. I have never seen that before. What are the specifics? Was this bike under water?

Looks like someone shot the tank full of urethane foam and closed the cap.

You....have your work cut out for you. I wonder what the carb bowls look like?

Holy crap.
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Steve_in_Florida on April 17, 2013, 04:53:55 PM
Quote from: not a lib on April 17, 2013, 04:08:17 PM

It's fresh in my mind because I just dealt with it last weekend... can't imagine why it didn't want to open.

(http://i643.photobucket.com/albums/uu159/rktmanfj/1990%20FJ1200%20project/20130414_130100_zpscf772471.jpg)


Ewwwwww!   :bad:

Title: Re: Removing Gas Cap Assembly Without a Key
Post by: rktmanfj on April 17, 2013, 05:00:11 PM
Quote from: Pat Conlon on April 17, 2013, 04:53:35 PM
Holy moly, what a mess. I have never seen that before. What are the specifics? Was this bike under water?

Looks like someone shot the tank full of urethane foam and closed the cap.

You....have your work cut out for you. I wonder what the carb bowls look like?

Holy crap.


Randy's gonna find find out next week.    :biggrin:

I was on the fence about doing them myself until I saw that.  I think this is a job for the ultrasonic tank.

The bike say for 3 years under a tarp, IIRC.  I can tell you that the liquid remaining in the tank smells just like the stuff in a friend's parts washer.  That cheap-ass habitually dissolves styrofoam in there to avoid disposal fees.   :shok:

Title: Re: Removing Gas Cap Assembly Without a Key
Post by: FJSpringy on April 17, 2013, 05:33:05 PM
Quote from: not a lib on April 17, 2013, 04:08:17 PM


(http://i643.photobucket.com/albums/uu159/rktmanfj/1990%20FJ1200%20project/20130414_130100_zpscf772471.jpg)


you keep your lunch in the fuel tank  :wacko2:
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: movenon on April 17, 2013, 05:54:40 PM
Holy crap batman !!!
On the lock... Take it up to a locksmith and have him pick it open.... If I was there I would do it for you... Its a simple lock.
George
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: FJSpringy on April 17, 2013, 06:03:50 PM
BTW I presume that you have removed the filler unit from the tank and you are playing with it on the bench.

(http://i1228.photobucket.com/albums/ee445/FJspringy/P1010002.jpg) (http://s1228.photobucket.com/user/FJspringy/media/P1010002.jpg.html)


(http://i1228.photobucket.com/albums/ee445/FJspringy/P1010007.jpg) (http://s1228.photobucket.com/user/FJspringy/media/P1010007.jpg.html)


off a 92
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: racerrad8 on April 17, 2013, 06:30:58 PM
Quote from: not a lib on April 17, 2013, 05:00:11 PM
Randy's gonna find find out next week.    :biggrin:

Oh boy...

That's okay, I am up for a challenge.

Randy - RPM
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Pat Conlon on April 17, 2013, 07:41:33 PM
Randy, you need to start a 'rouges gallery' of pictures. I bet you see some strange stuff.
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: racerman_27410 on April 17, 2013, 08:22:51 PM
Barnacles!




KOokaloo!




Title: Re: Removing Gas Cap Assembly Without a Key
Post by: racerrad8 on April 17, 2013, 08:51:50 PM
Quote from: Pat Conlon on April 17, 2013, 07:41:33 PM
Randy, you need to start a 'rouges gallery' of pictures. I bet you see some strange stuff.

You make the gallery, I'll post the photos...

Randy - RPM
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Pat Conlon on April 17, 2013, 09:04:15 PM
Ok, I'll work on that. First I'll post the shim kit info. sticky in the Maint.Flies.

UPS just dropped off my carbs. Wow...that bubble bath you gave them sure makes them look like new...

Thanks Randy well done!
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Firehawk068 on April 17, 2013, 09:31:33 PM
Quote from: FJSpringy on April 17, 2013, 05:33:05 PM
Quote from: not a lib on April 17, 2013, 04:08:17 PM


(http://i643.photobucket.com/albums/uu159/rktmanfj/1990%20FJ1200%20project/20130414_130100_zpscf772471.jpg)


you keep your lunch in the fuel tank  :wacko2:

So thats what Vegemite looks like?
Someone smuggling it into the US in FJ fuel tanks?
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Arnie on April 17, 2013, 09:44:11 PM
Unless you want to learn lockpicking techniques, you'll either have to drill out the lock and rotate the barrel manually or take the tank to a locksmith.
The locksmith will probably not charge too much, and will be able to make a new key for the cap so you can still use it.

Arnie
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: fj11.5 on April 17, 2013, 10:47:30 PM
Quote from: Firehawk068 on April 17, 2013, 09:31:33 PM
Quote from: FJSpringy on April 17, 2013, 05:33:05 PM
Quote from: not a lib on April 17, 2013, 04:08:17 PM


(http://i643.photobucket.com/albums/uu159/rktmanfj/1990%20FJ1200%20project/20130414_130100_zpscf772471.jpg)


you keep your lunch in the fuel tank  :wacko2:

So thats what Vegemite looks like?
Someone smuggling it into the US in FJ fuel tanks?
sssshhhhhhhh you'll blow my cover,
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: jscgdunn on April 18, 2013, 08:54:44 AM
Betwen my friend and I we have had about 10 Yamahas around here with vintage from 82 to 92.  There are few different sets of keys, but we have found that often a key from another bike will work.  For instance, the key from my Son's 82 XS 400 was the same as the 84 FJ, which was the same as another 84 FJ tank.  Possibly a wrecker might have a bunch of keys you could try?

Jeff
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: Dan Filetti on April 18, 2013, 08:57:35 AM
Quote from: jscgdunn on April 18, 2013, 08:54:44 AM
Betwen my friend and I we have had about 10 Yamahas around here with vintage from 82 to 92.  There are few different sets of keys, but we have found that often a key from another bike will work.  For instance, the key from my Son's 82 XS 400 was the same as the 84 FJ, which was the same as another 84 FJ tank.  Possibly a wrecker might have a bunch of keys you could try?

Jeff

Maybe it's "the same key" or more likely, it's worn tumblers in the lock, allowing 'similar keys' to be used.  A good thought though, a similar key from another Yamaha may just work.

Dan
Title: Re: Removing Gas Cap Assembly Without a Key
Post by: rktmanfj on April 18, 2013, 09:05:16 AM
Quote from: Dan Filetti on April 18, 2013, 08:57:35 AM

Maybe it's "the same key" or more likely, it's worn tumblers in the lock, allowing 'similar keys' to be used.  A good thought though, a similar key from another Yamaha may just work.

Dan

Probably this, IMO.

I found out by accident that the key to my brand-new ignition switch will also work the gas cap and seat lock on my '89.


Title: Re: Removing Gas Cap Assembly Without a Key
Post by: jscgdunn on April 18, 2013, 10:45:35 AM
Typically the locks sets are not very worn.  None of these bikes have over 70,000 KMs and the XS 400s had less than 10,000.  Up here in the great white north they just do not get much use.  Next rally it would be an interesting exercise to see how many keys are interchangable.