How-to: re-key your gas cap

[blackonwhite99r6]

Well I have seen the ignition and trunk lock how-tos but they didn't help me any so I decided to pioneer this shit. Please excuse the small and crappy pictures but you will get the point and once you know how to do it, it is VERY easy. You might have bought a new tank and want to use your old key or you want to use a different key on your current tank, either way I'm gonna tell you how to do it.
Here it goes:

Tools needed:
Screwdriver
Bobby pin
Half a brain
Pliers

Step 1:
Take your old cap off of your tank by unscrewing 5 screws, unlocking the cap and unscrewing one more screw inside. Make sure you plug your tank with a cloth so shit doesnt get in your tank. My old cap was different than my new cap, but we will get to the details of that later... Here are the two different caps off the bikes

[blackonwhite99r6]

Step 2:

Flip the cap over and you will see two screws...unscrew those two screws and

you can just lift everything off....... make sure the cap is flat down when you pull

off the main retainer because there are 4 springs and a ball underneath that can

fall out. Here is what it should look like before and after. (I also removed one

more screw while I was tinkering with it, its small and close to the hinge,

(see the hole?) pop that off and you can clean out your little flip up lock cover to

clean it and make it new and smooth again, or if it jams in the up position,

cleaning dirt out will help too but notice the metal "leaf spring" don't lose it).

[blackonwhite99r6]

Step 3:

Now that you have everything apart, take a look at the black rubber seal that

goes around the two prongs.....use a broken in half bobby pin, push down on one

side and pull it out, then tip it upside down and just tap the metal washer out

in good lighting you should see a shim that when you put the key in and turn it,

the shim rotates. Use the broken in half bobby pin (broken in half for the hook

action) to push that shim in towards the lock while pushing the lock in to slide it

out towards the key hole (make sure you take the key out before you do it or the

shim won't push in all the way). It should slide right out.

[blackonwhite99r6]

Step 4:

Now if you have two gas caps that you are doing then repeat steps one through

three. Now use pliers and pull out all the shims, you may have to wiggle them a

little to get them out properly but they will come (make sure the little springs dont

fall out). Once you get the shims out you should place them so that the bottom

one is on bottom and the top one is on top and they are all in order so you dont

forget. Now take the shims from the old gas cap and put them in the new gas cap,

they should slide right in, just make sure the L part is facing the spring, it wont fit

any other way so don't worry about that, just get them in the right order.

Edit* One lock assembly is shorter than the other because I dremeled a bunch of stuff to figure out how to get it out, dont worry about that,

and the bobby pin pic should be in the post above but thats okay, you still see the shims

[blackonwhite99r6]

Step 5:

Make sure that the key works so you dont put it in to find out you put the shims

in wrong, that would really stink, to make sure it fits slide the key in, if any shims

are protruding and not flush with the lock, you have them in wrong. They should

protrude in pairs because if just one is protruding then I dont know what to say.

Now take the newly shimmed lock and put it in the housing like shown in the pic

below. You will see the grooves for the shims, but on the lock there is a spot that

comes down more than the rest, make sure you have it right side up and not

upside down. You will see what I am talking about, its just hard to explain, but

I don't think it goes in the wrong way anyways. Now use the bobby pin to press

the shim in towards the lock and slide it down all the way till it clicks. Now turn the

key just to make sure that it works.

[blackonwhite99r6]

Step 6:

Now re assemble everything.....for me it was a little harder than just following the

disassembly process and I hate it when I don't have a reference when putting

something back together so I will help you out a little. IF you removed that third

screw to clean your little hinge then you will need to start by laying the cap down

like in the picture (gas cap 15). Put the springs on and put the little ball in the

square box like in the picture (gas cap 14). Dont forget to keep the rubber gasket

on there and the metal leaf spring (refer to shiny part in gas cap 15) before you

slide it down onto the two mounting poles. Make sure it seats correctly then

install the little third screw. Now take the main retainer and put it on top of the

springs, then put the little plate on top of that, then the locking part (gas cap 13).

Then install the 2 screws, flip it over and make sure everything works right, and

install the small rubber gasket that goes around the keyhole. Now install it on

your bike by keeping it open, screwing in the inside base screw and then closing

the cap and screwing in the other 5.

[blackonwhite99r6]

SIDE NOTE, since my gas caps were different I couldnt just switch the whole

housing out. Look at it in the pictures and check out this thread-

http://www.r6messagenet.com/forums/s...ad.php?t=89667 as a reference.

If you have two of the same gas caps you can just take out the three screws and

switch the whole assembly so that you dont have to pop it out and rekey it, that

might save you a total of like 10 minutes. If you have any questions while you are

doing it, feel free to PM me

Diclaimer-If you are a dumbass then I am not responsible

[R6AJ]

That looks like fun

good work

[leukus]

Stupid question.

I took my gas cap off, and like a idiot i didn't pay attention to what screw went where. i assume all 5 screws would be the same. Once i got them all out i can't remeber which 2 were the long ones and which ones were the short ones. Anyone help??

[blackonwhite99r6]

I think the shorter ones wont reach where the long ones go, I took mine out a while ago, but Im almost positive on this one...