04 XB12R Gas Cap Issue

[tut32359]

Hi All, We just got my Son a 2004 XB12R Firebolt. Less than 5000 miles on it .It has been setting up for awhile. We bought it from a friend of ours and it needs minor work done such as all the Rear taillight and front running light stem are broke. The clutch cable lever is broke and we need to get a rear taillight switch.All these are eaey fixes.
Motor turns over strong,but we cant get the locking gas cap to open.We have lubed it and let it set, but the key will not turn inside the cap. The ignition and side lock work perfectly. There is a tiny hole on the side and we even tried the lube there, it came back up out of the lock and around the cap itself, but still wont budge.
Any ideas? Will I have to replace the assembly ,is I do there is no mounting bolts, Im assuming they are under the cap it self. I would really appreciate your help. Its driving him crazy ,and he is ready to ride. Thanks

 

[ztied]

Is it possible that it uses a different key

 

[tut32359]

No, same key fits all. Gas cap hasn't been replaced.At least that what I was told from original owner.

 

[Shawns]

I have a factory led tail light $35 shipped if you need one. As far as the cap, you may have to drill it out. I would spend the extra few bucks and get a keyless cap http://www.slingshotracing.net/cata...rs1190rx-keyless-race-gas-fuel-cap-p-868.html

 

[tut32359]

Thanks for the info on the keyless cap. Those look good. Are those taillights stock for the XB12. Could you send me a pic of them. Thanks

 

[tut32359]

Would drilling out the old cap lock cause any metal shavings to get into the tank?

 

[nicholas900]

That really sucks. Keep trying the lube till it is pointless. That would be the easiest if it breaks free. Also consider it might be the wrong key and you might be SOL. Can you cross reference VIN and key code? Dunno.

Here's some light shed on what you can't see.

The cap has a green plastic cup that spins by turning the key to lock in plastic tabs into the cut out tabs of the (thin cast) hold down ring which is bolted to the tank under the fuel cap. Pencil points to the plastic tab that holds the cap in.

I would try to avoid drilling, as you mentioned the drill shavings would eventually get into the tank. Not sure the best way to remove it. Assume you will need a new cap. I would screw a big honking lag bolt into the key hole and try to pull out out forcefully with a slide hammer. Something will give, either the plastic ear on the cap or the thin cast retaining ring.

If a chunk falls in it could be removed by pulling the fuel pump out. Not to tricky and leaves a big hole to poke around. Guess I rather try to fish out a big chunk than worry about tiny drill shavings getting through the fuel filter.

Best of luck!

 

[tut32359]

Thanks Nicholas, That's what I needed to know.The key is the correct one. I was thinking the inside of the cap was metal and rusted(as most im used to are).
The plastic tab pic helps tremendously,shows me what im dealing with. So the whole cap comes off instead of it being hinged like the tab over the keyhole.I think if I apply downward pressure to the top and my son keeps trying to turn with the key we might just get it off.When we do we are going to get one from SlingShot Racing as Shawns suggested.
Thanks very much for the pics and your help!

 

[nicholas900]

Yup. Whole cap comes off. There are two plastic tabs 180° apart. At least you know what your dealing with now.

Keep us posted how it works out.

 

[mrlogix]

Yup. Whole cap comes off. There are two plastic tabs 180° apart. At least you know what your dealing with now.

that was cool. Gets a +1 from me.

 

[ztied]

If you drill in just the key hole part of the lock on the gas cap,and do it easy, you will not get any shavings in the thank. Use like a 1/4 in drill bit go down about 1/2in maybe a little more, at a certain point all of the keyways will be loose you can use a flat head screwdriver and unlock the gas cap. If you do it right you can pull out the lock assembly (from the bottom after it is opened) and replace it.) nothing will fall in the tank unless you accidentally drill all the way thru it the gas cap.

 

[ztied]

And you can still ride the bike and just carry the screw driver to open the gas cap.

 

[tut32359]

Guys I really appreciate the great advice.I will keep this post updated. Thanks

 

[Shawns]

PM'D ya

 

[niskalaukaus]

One thing about keys.
Sometimes locks and keys wear on use, so if you have to keys, one can work on all locks and the other doesnt work for example on gas cap. Happened to me on another bike.

So do you have both keys and have you tried both on the cap?

 

[tut32359]

Yep, tried both keys. Im still working with it,but keys will not turn at all.

 

[tut32359]

Well i drilled the keyhole with a 1/4" bit and went about 1/2" deep before it caught and popped right off. Around the cap flange was rusted, we are cleaning that. Drain the gas,cause it has been sitting up for awhile and run into another problem.I posted it in the troubleshooting area. Its mainly the best way to clean the tank, cause it had a oily sticky mixture come out also,this came out after about a gallon of very bad gas was drained.