Trouble shooting questions

[EMTbiker]

Hi all,

First time back in who knows how long, was gonna sell my GS but the old girl is still around can't stand to see it gather dust anymore so it's time to get to work. So this is going to be a ongoing series of questions for those who know what the hell they are doing, so when I come across something that's screwed up I come to you guys for guidance.

So first on the chopping block is this screwy gas tank lock. I got a new key made for the ignition which works great but the key will only slide in not turn. I'm assuming they are two different but similar keys, then the other kicker is I cant get the gas cap unscrewed to take the lock mechisim out. My question is this can I get by with drilling out the messed up screws and replacing them? Plus there's some junk rattling in the tank so I really need to get it off to see what's inside.

So any help would be nice, it's great to be back btw!!

Regards

[adidasguy]

Gas caps and ignition should be the same key, and the seat lock.
On the gas cap, 4 bolts hold it in. The others are decorative. Gas cap can not be removed unless you unlock it.
Possibly it is rusted. There is a spring loaded gasket, so be sure you press down on the cap to release the pressure from the lock tangs when you turn the key.
Otherwise, you need to replace it. To get it off: one whomping big ass screwdriver and a good wrench to turn it.
There are some keyless gas caps. My favorite is Roaring Toyz. Expensive, buy really nice.

PS: Since the keys are double sided with the same on both sides (or nearly the same), try reversing the key. Also try turning a little while sliding in and out (kind of erotic, well, not really bit it sound that way). Remember to press down on the cap when  you try to unlock it.

[Janx101]

  ... sliding keys addy?! .. 

umm ... no nevermind!   

[adidasguy]

To be truthful, it is referred to as "raking  the tumblers".
Slight turning pressure on a key. Slide in and out. Many times a similar key (not the right one) will rake the tumblers and it will open.
Based on the ides that all tumblers are not on a perfect line. Little pressure and the one tumbler will click and it will turn a micro amount. Then the next. and so forth. Sort of the basis for picking a lock. (Well, it really is!)
(Tumblers, pins, wafers, whatever. Kind of the same for any. Our locks are wafer locks.)

[EMTbiker]

Yeah the decorative Allen heads threw me for a loop at first lol I got two of the actual bolts out the other two spin for days but go nowhere, I've tried every mechanics trick I know of to get them to do any thing but they just spin. As far as the lock goes ( and I too will make this as less erotic as possible lol) I've tried sliding it in out and repeatedly, sprayed it with wd40, tapped the edges with a screw driver trying to break loose the mechanism but I've gotten no where. I wanted to salvage the gas cap if I could but I'm thinking I might have to waste it in the name of progress. So sounds like my options are to drill out the lock or smash the lock with a screw driver, sounds like some grand theft auto moves haha but I will try as Adidasguy recommended as well cuz it would be nice to save it.

[adidasguy]

Crap ones I stick in a big ass screw driver then turn hard clockwise with a wrench or good pliers and destroy the lock while opening it.

Interesting: there is a limited number of keys possible. I got a used 89 tank from the Netherlands. Gas cap was on. My 2009 key magically fit it!

If you have other keys at your disposal, try them! You might get lucky like I did.

[EMTbiker]

Huh that is interesting, I will try "picking" it but my gut feeling is that the lock is shot and must be violently destroyed 

[Toledo Jim]

I was told by a locksmith that the gas cap and the seat locks were keyed differently. 

When I replaced my gas cap he used the new key AND the old key to figure out how to make me a key that worked on both.

I would take it to a locksmith and let him try to pick it, then try to make me a key that would work on both.

Good luck.

Jim

[adidasguy]

Yours may have been different due to one being changed.
From the factory, all are keyed the same. Hence only one key with the bike and one key code thingy in your owners manual.
It is known that the seat only has 4 wafers while the tank has more and the ignition as all of them (6 I think).

[EMTbiker]

Now I called a dealership to see if maybe a key could be made by the serial number like a friend did on a Harley but they said they couldn't.

[Toledo Jim]

Yours may have been different due to one being changed.
From the factory, all are keyed the same. Hence only one key with the bike and one key code thingy in your owners manual.
It is known that the seat only has 4 wafers while the tank has more and the ignition as all of them (6 I think).

You may be right, it has been a while.

However, I still think a locksmith is the way to go for the simplest and cheapest fix for this.

[EMTbiker]

Yours may have been different due to one being changed.
From the factory, all are keyed the same. Hence only one key with the bike and one key code thingy in your owners manual.
It is known that the seat only has 4 wafers while the tank has more and the ignition as all of them (6 I think).

You may be right, it has been a while.

However, I still think a locksmith is the way to go for the simplest and cheapest fix for this.

I had to have one made for the ignition cuz I had no keys at all and that was 40 bucks, kinda seemed like highway robbery to me.

[adidasguy]

Now I called a dealership to see if maybe a key could be made by the serial number like a friend did on a Harley but they said they couldn't.

The book says:
When you get a GS500, you get a plastic tag with the key number on it. You are to wrirte that number in your owner's manual in case you lose the key.

Given that, $40 for a locksmith is probably not bad. Remember they have to first determine the key so they have to pick it or take it apart. Half hour probably so not bad for specialists to do that.

Another option is buy a new lock, tank, seat set for $65-$150. Or someone may sell them to you that is parting out a bike.

Lost keys are never fun.

[EMTbiker]

Yeah I guess that isn't so bad,  I got the bike from a friend after it had sat for awhile, no keys no title, had to call the state police and see if it was stolen luckily it wasn't an the title wasn't a big deal.

[EMTbiker]

Well I got it out, had to resort to violence however. Tried picking it, tried soaking it in pb blaster and got nothing, it was so seized up the age old screw driver trick didn't work so it got drilled out. RIP gas cap

[EMTbiker]

Ok well we have progressed to trying to putting her back together but there is more vacuum and gas lines than there are stars in the universe, so does someone have a picture or schematic of the lines going to the carb?