Removing locked gas cap, no key
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Thread: Removing locked gas cap, no key

  1. #1
    Senior Member ZacoWacko's Avatar
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    Removing locked gas cap, no key

    Well in my further quest to turn my property into a bike salvage yard, I found an 05 xt225 for $100, to go with my ttr225. All these to go to my eventual tw225 build.

    Anyway, the gas tank on the thing looks pretty damn good on the outside and don't you know, the guy no longer new where the key was. Bikes pretty much disassembled.

    Cap is pretty well scarred up, looks like he briefly tried to get it off.

    What's the easiest route to get this thing off, if I'm not worried about the cap. Just wondering if the tank is completely rusted out, so not interested in paying a locksmith, to find out the tank is rusted out. Drill it?

    Thanks as always guys.

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    Senior Member PlacerLode's Avatar
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    twist it off with channel lock pliers it comes off like a hot knife through butter and does not damage the tank

    btw you can drill the tumblers but you still have to rotate the actuator to retract the lock bars but it's a lot of unnecessary effort when they twist off so easy you'll be shocked
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    Senior Member ZacoWacko's Avatar
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    Quote Originally Posted by PlacerLode View Post
    twist it off with channel lock pliers it comes off like a hot knife through butter and does not damage the tank

    btw you can drill the tumblers but you still have to rotate the actuator to retract the lock bars but it's a lot of unnecessary effort when they twist off so easy you'll be shocked
    I thought about a strap wrench, but was worried that may damage the tank. So those little tabs on the cap won't f up the tank huh

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    Super Moderator JerseyJeeper's Avatar
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    I'm sure Fred has done it and I haven't looked at the tabs recently but that concerns me as well. There are two different gas cap styles. Does this method apply to both Fred?
    Husqvarna TE300i Fuel Injected 2-Stroke 2019
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    Senior Member ZacoWacko's Avatar
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    Ya, i dont want to run the risk of the lock bars flattening out something in the tank. Not sure how i would go about fixing that.

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    Senior Member PlacerLode's Avatar
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    if it damaged tanks I would never recommend it but as I stated it's like a hot knife through butter there as zero security on a TW tank the tin plate holding the lock bars is very soft compared to the steel tank material which is actually substantially higher quality metal

    someone with a good grip could probably twist it off by hand
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    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by PlacerLode View Post
    if it damaged tanks I would never recommend it but as I stated it's like a hot knife through butter there as zero security on a TW tank the tin plate holding the lock bars is very soft compared to the steel tank material which is actually substantially higher quality metal

    someone with a good grip could probably twist it off by hand
    Quote Originally Posted by ZacoWacko View Post
    Ya, i dont want to run the risk of the lock bars flattening out something in the tank. Not sure how i would go about fixing that.
    Okay, who's going to be the first one to try this technique out with before and after pics ?

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    Super Moderator JerseyJeeper's Avatar
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    SO this applies to both style caps, new and old? Just clarifying the application, not questioning the method.
    Husqvarna TE300i Fuel Injected 2-Stroke 2019
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    Yamaha TW200Z - 2010
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    Kawasaki Prairie 650 - 2002

  10. #9
    Senior Member PlacerLode's Avatar
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    Quote Originally Posted by TW-Brian View Post
    Okay, who's going to be the first one to try this technique out with before and after pics ?
    I've done it a dozen times but never figured I'd need to prove it lol

    you can lead a horse to water but you might have to shoot it to get it to put it's head down

    I don't care if a horse drinks or not
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    Senior Member PlacerLode's Avatar
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    Quote Originally Posted by JerseyJeeper View Post
    SO this applies to both style caps, new and old? Just clarifying the application, not questioning the method.
    never had to do an early style cap all mine have been unlocked I wish the later style had the same option

    I'm repeating myself a lot on this thread but I was literally shocked at how easy these come off

    I had a primo 2009 and the primo 76 mile 2003 I still have that came with no keys so I've done this on showboat TW's not just beaters
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