| Author | Message | ||
     Coldwind |
Buell lovers out there! This past Thursday I finally broke my key in the gas cap. I was almost home stopping for gas, about 3 miles from the house. Had to leave the bike and get the trailer to get the bike home. Sounds similar to any of you people? Well,........... I spent the day running around to find another set of keys, won't do me any good if I can't get the gas cap off, right? Got another set of keys ordered from the factory and will search the other spare that I can't seem to find in the hay sack. In the mean time I had read in here about drilling out the cap to remove it, then having to remove the fuel pump to clean out the shavings from drilling it out. Then having to buy another cap that cost about $65, ouch that hurt! I just got my cap off and working with the broken key still in the tumbler. The top half of the key still locks the gas cap and no more long key to break again. As I was working on the cap I took the rubber out from around the cover and was able to pry off the round cover carefully and you will see the two little springs that keeps the key slot cover closed, remove that carefully and you will be able to see the broken key. I sprayed some WD 40 into the tumbler to get the pins and the key moving again. I was able to push the key down into the slot some more and proceed to push the key in further with my broken key and bingo the key was able to turn and open the cap! Do that a few times and make sure you can get the cap off. Now putting the top of the key slot cover back together, you will need to install the rubber piece that you pulled off first. Spray some WD 40 on the rubber so it will install easier. You may need a jeweler's screw driver to get the rubber in just right, then the slot cover with the springs then the steel cover. I used a wooden dowel and a mallet to kind of pop the cover back in place. I did not have a chance to check with a locksmith and I am sure that he could get the broken key out and you can use the regular key (the one like you had before it broke) if you wish. Just remember to lube the tumbler from time to time and you shouldn't have any broken keys like I did.  (Message edited by coldwind on August 22, 2009) | ||
| Blake |
Paragraphs are your friend. | ||
| Coldwind |
Sorry about that Blake, I'll do better next time, I don't write much and wanted to write down the help at the spur of the moment. I hope it will be helpful. | ||
| Kalali |
You left out the most important part which is how did you take the cap off with the broken key stuck in there....? | ||
| Coldwind |
Kalali, The broken part is down in the tumbler and the other part of the broken key is still on the key chain or ring. I pushed the bottom half of the broken key into the tumbler to match up to the pins. You use the upper broken part of the key to insert till it matches the bottom in the key slot, then you can turn the lock to unlock the cap. You still use the broken key to remove the gas cap, the upper part and you won't be able to use it in the ignition any more. (Message edited by coldwind on August 22, 2009) | ||
| Tiltcylinder |
Use a coping or scroll saw blade with the pin removed or ground off. The teeth are tiny and sharp, then insert where there's room and pull back. The tooth bites into the soft key and will usually allow you to pull it out enough to grab with pliers. Kind of the standard homemade locksmithing tool... Higher teeth per inch will allow the back (flat) side of the blade to be ground down, allowing use in a really small keyhole. | ||
| Kalali |
Got it. Thanks. |
