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Old 07-24-2009, 05:19 PM   #1 (permalink)
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Default 05 ZX6R gas tank lock stuck

Hello everyone! I am new to the forum but am 27 and have been riding on two wheels for twenty years. I have an 05 ZX6R that sat in my garage for a year and a half without being ridden. When I serviced it to get it running again everything went smoothly except that my gas tank lock is stuck. I broke a key trying to get it open and a lock smith couldn't open it either. I pulled the tank off and the fuel pump and flushed it out really well. I can't get my hand in to access the lock from the inside. I filled it with gas and put it all back together. I believe my power commander needs reprogramming as it wouldn't start at first. I disconnected it and put the factory wires back on and it fired right up. The bike runs great however without being able to access the gas tank without pulling it and the fuel pump off I can't ride for too long. Does anyone have any ideas how I can get this cap off? Since it's locked I don't know how to pull it out to even replace it. What do I need to do? Also the power commander sitting for so long...does it reset itself and just need to be re programmed or could I have ruined it somehow? Thank you for any help you can offer.
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Old 07-24-2009, 05:24 PM   #2 (permalink)
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squirt some oil in there and try to turn it with a screw driver while pushing the cap down , if that doesnt work drill out the lock , do noy pry up on the cap or you will damage the lip on the filler hole and that will ruin the tank
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Old 07-24-2009, 05:56 PM   #3 (permalink)
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Thank you for the reply. I did soak it in some oil that the lock smith gave me and it's still stuck. Can a screw driver turn it if it's locked? If that doesn't work can you give me a detailed process how to drill this lock out? I've never done it but definately have the tools to do so. Thank you again.
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Old 07-24-2009, 05:58 PM   #4 (permalink)
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i had the shop do it. I seriously dont know what they did to get it off but i do remember getting drunk that same night, taking my key and hammering it in. When i hit my finger the 2nd time I realized I do not need a hammer near my bike in that condition.
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Old 07-24-2009, 10:38 PM   #5 (permalink)
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had you not broke the key off you could just hammer a screw driver in there and twist it back and forth with a pair of vice grips , you obviously would need a new cap after that though , buying bikes from the insurance auctions makes you good at this technique ...lol

as far as directions for drilling out the lock goes its pretty simple , you drill out the center of the lock so the tumblers fall out and then you can turn the lock with a screw driver , just dont drill too deep you just want to go as deep as the tumblers
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Old 07-25-2009, 02:05 AM   #6 (permalink)
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I managed to get the key out so your technique of hammering it in may just work. Will the bike run if the cap isn't sealed down after doing this?
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Old 07-25-2009, 03:07 AM   #7 (permalink)
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yes but if you do it right you will be able to open and close the cap , you will need to carry a screw driver with you to get gas till you get a new cap
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Old 08-19-2009, 09:06 PM   #8 (permalink)
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Thank you all for your replies so far. I took the bike up to a locksmith friend of mine and here is what happened. He picked the lock and got it turned slightly so the tumblers stuck open. Something my key was not strong enough to do....I guess those spring steel lock pick sets are pretty sturdy....Anyway...we couldn't turn it any further. Ended up using a small flat screw driver to twist it. The locking mechanism completely ripped apart in multiple places around the casing and we were then able to pull it out. Under neath that is a rectangular depression in the metal. I found a large bladed screw driver and twisted the heck out of this until I freed the two prongs holding it down to the inside of the tank. Once open I removed the entire piece...took it apart....greased the springs and prong slides and basically did maintenance on every part of it. Now I can open and close this using my screw driver and it still looks like it locks with the flip down cover. I'm not really worried about it or anyone messing with it. I'm either riding it in some twisties ....eating for maybe 30 minutes in eye sight of it or it's in a garage. Was thinking to replace the entire thing with a vortex keyless. Read some opinions on the locking aspect being a worry for some but I'm not worried about it here. What's the best quality keyless gas tank access system for this bike?

Also I have pictures of the inside of this thing once the lock is removed as well as the underside....both disassembled and reassembled if anyone thinks it would help I'll post some.
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Old 05-31-2011, 01:03 PM   #9 (permalink)
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Sorry to bring up this old thread, but I had the same problem on my 09 ZX6R. It seems as it had some mineral deposits on the lock.

My fix was spray liberally with WD40 and then tap the key in with a rather large screwdriver handle. Emphasis on TAP and not hammer. After tapping for 5 or so min like an idiot the lock became free. Once opened I sprayed it out with WD40 and it now works like new. I haven't seen any WD40 make it past the lock into the fuel tank so IMO you are safe to spray the crap out of it.

I think it may have been mineral deposits from water that got the key mechanism stuck and tapping on it along with WD40 broke it loose. I don't see a need to replace the lock .
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