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Gas Cap Locked Closed (and busted)...

Discussion in 'XJ Technical Chat' started by HoserT, Jan 5, 2009.

  1. HoserT

    HoserT New Member

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    Hello all,

    Just after Thanksgiving, I removed the tank from my bike to get started on removing some rust. At the same time, I took apart and cleaned the gas cap which was only intermittently working. Now, it doesn't work at all, and is locked closed.

    Has anyone figured out how to rig something to open the cap without causing too much damage?

    Thanks
    T
     
  2. Altus

    Altus Active Member

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    Depending on the year of the bike, the internal construction of the gas caps changed -- but you options are limited nonetheless.

    Does the key turn, but not open? Or is it not turning at all?

    Esentially, you either need to fiddle with it to get it to open, or you're going to be drilling it out and looking for a new gas cap or lock cylinder at least.
     
  3. flash1259

    flash1259 Member

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    What are you riding?

    my 1982 maxim had the same problem, i had to chip away at it intill i was able to use the screwdriver to twist the cylinder. once the lock is broken out there was a brass piece with a slot in it ian it opened without damaging the tank.
     
  4. Alive

    Alive Active Member

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    You could of course get a locksmith to look at it :)
     
  5. crewwolfy

    crewwolfy Member

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    I had a chunk of something in the bottom of mine, so I couldn't fit the key all the way in. Just took a big screwdriver and twisted. Now it does close, but never actually locks. Works for me, as no one's stealing or sabotaging my gas.
     
  6. HoserT

    HoserT New Member

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    So here's the whole story. The thing never actually worked right, so I disassembled and cleaned it when I drained the gas. Then I was in a rush to get to the store. So I reassembled it while talking to my Father-in-Law. So haste and distraction....

    I thought I assembled it incorrectly~ The cylinder turns, pulls two cast metal part, each with a little nub that engages the bolts. I thought I had those two cast pieces reversed from just looking at it, and in a moment of haste, installed the cap & closed the cap...

    I was right, and this was a bad what to check, huh? Now, the cap is locked shut.

    Sweet!

    Irritatedly,
    T
     
  7. Alive

    Alive Active Member

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    Oh.... That could be a problem.

    Not sure how you're going to get around that sorry :)
     
  8. SQLGuy

    SQLGuy Well-Known Member

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    If you've got a fuel gauge on your bike you make be able to remove the sending unit and reach in through the opening where it mounts to release the cap bolts.
     
  9. Altus

    Altus Active Member

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    Yup - sorry to say that unless you can go through the fuel gauge sending unit hole as SQL said, you're pretty much boned.

    The only other way in is a drill - even the screwdriver method won't work for you. I've had to do that once -- if I can find the photos I took I'll show you what I had to do.
     
  10. HoserT

    HoserT New Member

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    I had some spare time this evening, so I sat down with the tank and started fiddling with the cap. As stated previous, the cap never worked right, and always had trouble unlocking. Well, apparently it also has a rough time sitting flush with the tank.

    Just for the fun of it, I inserted the key, turned it, and started rocking the cap back and forth, side to side. After a minute or so of this treatment, it opened. I did end up putting a slight bend in that key though…

    However: “Yip!”
     
  11. TheHound

    TheHound Active Member

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    I know you're smiling.
     
  12. hammerheadx

    hammerheadx Member

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    Ride it. When you run out of gas, sell it for parts.
    :D

    I did the old hammer-a-screwdriver-in-there-and-twist-with-crescent-wrench trick.
    Now my Keychain is one of those circular disks with four flat blade screwdriver outlines. Nice and light and opens my tank in a jiffy.
    like stated in a post above, i've never had a big problem with peope stealing my gas and believe a locking gas cap on a bike is a nusance ONLY to the bike's owner.
    I mean, even if i lived in a hotbed of bike gas stealing skullduggery, how long did it take me to defeat the Fort Knox of fuel security that came with my Maxim?
    About 20 seconds and that's cause it was my first attempt and i took my time.
    That stupid lock isn't keeping any criminals from helping themselves to your fuel. It's only keeping YOU from putting more in, when it freezes up.

    And have any of genius' at Yamaha ever thought that a gas thief might see the lock and then simply go to the left side, under the tank and slice the fuel line at the petcock, turn to prime and drain in a bucket? Heck, that saves them the siphoning work from the top.

    Truly useless, trap-door-on-a-submarine engineering right there. :roll:
     
  13. coolalleycat

    coolalleycat New Member

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    if someone was going to steal your fuel they could easily do it via the petcock....right?
     
  14. schnarr

    schnarr Member

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    yeah but it would sure take awhile
     
  15. redcentre003

    redcentre003 Member

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    I read this post with interest as I have had the same thing happen to me. I only ride short distances to/from work and a tank of petrol can last 2 weeks or more.

    My gas cap was always a little stubborn when it came to unlocking and of course it decided to seize up completely when I went to fill up one day just before Christmas. Here I am, standing next to my bike at the gas station bowser struggling with the key and the cap, jiggling and prodding. Ten minutes later she reluctantly but very slowly turned into the unlocked position - I was so scared that I'd bend or break the key.

    When I got home I took the cap apart, cleaned it out, and flakes of rust fell out. Cleaned, lightly greased and then put back together. Works like a charm now but because I only fill up infrequently I spray a little WD40 inside the cap from time to time to keep it operating smoothly.

    And yes...you have to be very careful with the springs and the little brass tabs in the cap and make sure they are inserted correctly and operate as they should otherwise you could be stuck. Literally.
     

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