How to remove a locked gas cap AND make it "keyless"
Thanks for the write up! This is very timely since I just bought a basket case bike, without keys. The gas cap is locked in place and I was considering drilling it out. I'll try this method first! Thanks again.
Last edited by thrasher572; Jul 15, 2011 at 05:33 AM. Reason: Typo
Junior Member
Joined: Jul 2011
Posts: 4
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hmmm
I just followed this write up as my key somehow was misplaced
I picked the lock to UNLOCKED position and opened the gas cap
removed everything as the video showed
removed the cylinder with needle nose pliers
removed the 5 inner lock mechanisms
put it back together and it wont turn
its like it still locked
weird tho because there isnt any sliders to pick lol
its like the 2 prongs that slide out and catch the inside of the tank are locked
they wiggle against the springs but wont move
any ideas?
I picked the lock to UNLOCKED position and opened the gas cap
removed everything as the video showed
removed the cylinder with needle nose pliers
removed the 5 inner lock mechanisms
put it back together and it wont turn
its like it still locked
weird tho because there isnt any sliders to pick lol
its like the 2 prongs that slide out and catch the inside of the tank are locked
they wiggle against the springs but wont move
any ideas?
Junior Member
Joined: Oct 2023
Posts: 1
Likes: 0
Alright, this is going to be hit and miss for a lot of people, but I did it, and so can you. If you don't want to bother with all this you can send me your gas cap (locked or unlocked) and I'll convert it to "keyless" for you for a small fee plus shipping, just PM me.
Anyway, on to the write up. I'm missing a lot of pictures but it's pretty self explanatory as you attempt it.
First off, brush up on your lock picking theory here: http://aaronjasso.com/features/lock.php
Here's that annoying little bastard:
Attachment 59031
Here are the tools I made to do this. Old hacksaw blades are perfect for lock picks while ground away bent nails are good tension wrenches.
Attachment 59032
Now, easier said then done, but pick that lock! You will spend a lot of time trying to do this, but you will get it. There are 5 pins and the lock cylinder turns CLOCKWISE. There is something about these locks that make them VERY brainless to pick. On most locks, if you push a pin up too far it will still be a "locked" pin. On the gas cap locks once the pin passes a certain point, the rest of it's range of motion will be "UNLOCKED." Read the lock picking tutorial and you will understand what I mean.
Conquered:
Attachment 59033
If you want to make it "keyless," read on!
Go to 0:30 of this youtube video to see how to remove the lock assembly from the gas cap. NOTE: In the video you see him push the bottom of the gas cap towards the top of the cap. This causes the cap to lock itself again. SKIP THIS STEP or else you will have to pick the lock a second time.
http://www.youtube.com/watch?v=zV-WKMqZzds
The result is:
Attachment 59034
Once the gas cap is out, make sure the key cylinder is in the "UNLOCKED" position. If you grab the cylinder with needle nose pliers, the entire cylinder will slide out.
When the cylinder slides out, the pins will fall out rather easily. When the pins are gone, the cylinder locks and unlocks without a key.
Attachment 59035
Put it all back together!
Locked:
Attachment 59036
Unlocked:
Anyway, on to the write up. I'm missing a lot of pictures but it's pretty self explanatory as you attempt it.
First off, brush up on your lock picking theory here: http://aaronjasso.com/features/lock.php
Here's that annoying little bastard:
Attachment 59031
Here are the tools I made to do this. Old hacksaw blades are perfect for lock picks while ground away bent nails are good tension wrenches.
Attachment 59032
Now, easier said then done, but pick that lock! You will spend a lot of time trying to do this, but you will get it. There are 5 pins and the lock cylinder turns CLOCKWISE. There is something about these locks that make them VERY brainless to pick. On most locks, if you push a pin up too far it will still be a "locked" pin. On the gas cap locks once the pin passes a certain point, the rest of it's range of motion will be "UNLOCKED." Read the lock picking tutorial and you will understand what I mean.
Conquered:
Attachment 59033
If you want to make it "keyless," read on!
Go to 0:30 of this youtube video to see how to remove the lock assembly from the gas cap. NOTE: In the video you see him push the bottom of the gas cap towards the top of the cap. This causes the cap to lock itself again. SKIP THIS STEP or else you will have to pick the lock a second time.
http://www.youtube.com/watch?v=zV-WKMqZzds
The result is:
Attachment 59034
Once the gas cap is out, make sure the key cylinder is in the "UNLOCKED" position. If you grab the cylinder with needle nose pliers, the entire cylinder will slide out.
When the cylinder slides out, the pins will fall out rather easily. When the pins are gone, the cylinder locks and unlocks without a key.
Attachment 59035
Put it all back together!
Locked:
Attachment 59036
Unlocked:
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