HELP - MY KEY WILL NOT UNLOCK THE GAS CAP

[retcol]

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.

[FJmonkey]

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.

[jamesearthdrum]

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.

[Yamahahammer1300]

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.

[balky1]

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.

[retcol]

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?

[CutterBill]

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

[Urban_Legend]

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

[balky1]

If it is 1100 you can break the pins and repair the cap easily like I said earlier.

[retcol]

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?

[FJmonkey]

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.

[balky1]

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.

[red]

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.

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!

[retcol]

THANKS EVERYONE! 

[ct7088]

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