Gas cap off with no key?

[Folsoml]

Is there a secret that will allow me to get the gas cap off this 89 Katana 750 with no key? The PO gave me a key, but it does not seem to work. Notably, it is also different than the ignition key (is this normal?). I've been soaking the lock in penetrating oil for about 12 hours now with no luck.

[arsenic]

No, that's not normal. Usually you only need 1 key for everything.

[Folsoml]

No, that's not normal. Usually you only need 1 key for everything.

That's what I thought. The ignition key doesn't work in the tank either. It is completely different type of key than the (supposed) tank key.

[steves]

1) Try the other key
2) Try flipping the key (turn it 180*)

[Kreylyn]

Remove the tank from the bike. Empty the tank. Remove the fuel sensor.

If you have a key that is correct, then spray lube onto the 2 latches from the fuel sensor side. Spraying oil into the lock portion isn't going to do much for you, that isn't where it's sticking nomrally.

If you do not have a key and that is why it won't open, then you can try using a long screw driver or pry bar to force the latch open from inside through the fuel sensor hole. If you can get one to move, both will (they are linked) and that will help get it open if you need to replace the cap entirely.

Krey

[Folsoml]

Remove the tank from the bike. Empty the tank. Remove the fuel sensor.

If you have a key that is correct, then spray lube onto the 2 latches from the fuel sensor side. Spraying oil into the lock portion isn't going to do much for you, that isn't where it's sticking nomrally.

If you do not have a key and that is why it won't open, then you can try using a long screw driver or pry bar to force the latch open from inside through the fuel sensor hole. If you can get one to move, both will (they are linked) and that will help get it open if you need to replace the cap entirely.

Krey

It's looking like this is the problem.

Is that supposed to be coated in black tar?


That doesn't look right.


Well, THERE'S your problem.


I had a similar problem with a Yamaha tank once. I eventually cut it in half and made a clock out of it.

[arsenic]

If your gas tank and petcock look like that, what do you think the carbs look like?

[Folsoml]

If your gas tank and petcock look like that, what do you think the carbs look like?

Like this! I've been through them. This is a "before" picture.

[92xjunker]

Hope you can save the tank, I would just save my effort and find a better one. Try the rust dissolving chemicals that are out there.

[pnut1236]

Kreem job gone bad? It looks like some sort of coating more than rust

[Kreylyn]

Clean the tank well. I'd suggest not using an acid that will remove any good material. If you do clean it and it does not leak, then por-15 it and your set.

If it leaks... you may want to asses how badly it is. If just one or 2 small spots I would fix. If it was a whole section paper thin... time to move on to a better tank.

Krey

[shpielers]

If it leaks... you may want to asses how badly it is. If just one or 2 small spots I would fix. If it was a whole section paper thin... time to move on to a better tank.

A leaky tank can be fixed? Leaky as in with holes in it, or as in bad gaskets?

[Kreylyn]

A leaky tank can be fixed? Leaky as in with holes in it, or as in bad gaskets?

As in holes.

The tank is metal and can be welded safely when properly cleaned. If it's a large section you can even cut it off and replace with new sheetmetal if you have the skills to shape/work it.

Krey

[92xjunker]

Clean the tank well. I'd suggest not using an acid that will remove any good material. If you do clean it and it does not leak, then por-15 it and your set.

If it leaks... you may want to asses how badly it is. If just one or 2 small spots I would fix. If it was a whole section paper thin... time to move on to a better tank.

Krey

+1, I was thinking of the water based rust remover. It works very well.

[Folsoml]

Just to update, I WAS able to save this tank. It took a couple of weeks of soaking it in CLR and water with a bunch of sheet metal screws added to give it some abrasive cleaning action. Periodically, I would drain it and wash it out with dish washing liquid before refilling it. When I finally stopped having large chunks of gunk coming out with the rinse, I used an Eastwood tank sealing kit. This seems to have done the trick.

I was NOT able to save the gas cap--at least not the key-lock mechanism. After a professional locksmith was not able to get it off, I drilled out the pins and opened it with a screwdriver.