How to re-key a GSXR/TL gas cap lock to your ignition lock
Bear with me as I don’t know all the terminology used in the locksmith industry so I will use terms that are as descriptive as possible. The first step is to round up a few tools. You will definitely need a few very small flat head screwdrivers, a Phillips head screwdriver, a safety pin or a regular sewing needle. You may need a fine pitch metal file (mill file) as well depending on how well the tumbler hooks fit in the tumbler assembly once the new key is inserted. Get one ready to go just in case you need one.
Insert the old key in the gas cap lock (if the cap is mounted on a fuel tank) & loosen then remove the four Allen head bolts that secure the fuel cap to the fuel tank. Yes, you need to unlock the cap in order for you to remove the cap from the tank. Once you remove the the fuel cap set it on a rag with the latch or the side that sits inside the fuel tank facing you. This picture shows the two different keys I have, the metal one being the one that the fuel cap lock came with, the rubber tipped one being the one I keyed the lock to. This shot is from the first lock I keyed, the second lock I re-keyed used 2 rubber tipped keys.
Using a Phillips head screwdriver remove the two screws that secure the steel latch to the cap assembly. Be careful when removing the latch as there is a small spring that pushes the latch into position which doesn't allow the cap to flip open unless you put the key in the lock & turn it. You don’t want to lose that spring! The picture below shows the position the spring needs to be in when you put the latch bracket back on the bottom of the fuel cap.
It is a good idea to remove the gold circular plate that is under the latch you just removed along with the plate with the rubber gasket beneath it that seals the top of the fuel tank. Under the second plate you will find four more springs, those are gold in color. Note, you don’t need to remove these plates & springs but since they were secured by the latch you removed it is a good idea to do so to clean up stuff in there. Technically you could just take the two screws you removed to expose the tumbler assembly & screw them back into place. That would have kept those plates in place. Do it either way depending on how you feel.
With the underside of the tumbler assembly exposed you will now find a metal washer in the slot around the tumbler. Remove it & under it is a rubber o-ring washer. Grab that safety pin & gently pry that rubber o-ring out of there without damaging it. Take your time & work your way around that o-ring & it will eventually pop out.
When you get that rubber o-ring out of that slot you will find another, pretty beat up metal washer/spacer under that o-ring. Remove it as well. It doesn’t look anything like the top washer you removed so there is no way to confuse the two washers. This is the order they will go back into that slot around the tumbler.
Here is a nice close-up image of how that tumbler sits inside the cylinder machined out of the fuel cap assembly. Note that copper colored tang that you can barely see deep in the cylinder bore below the tumbler.
That is a spring loaded latch or hook you will need to press into the tumbler assembly in order to free up the tumbler so you can remove it. That latch holds the tumbler firmly in place. It is recessed & there isn’t much space to access it around the outside of the tumbler. So you will need to find a thin flat head screwdriver that is sturdy enough to be able to withstand the force it will take to push that latch into the tumbler but is thin enough to slide between the cylinder wall and tumbler. This part of the keying is probably the toughest part & there is a technique you need to use in order to make this a lot easier. Seeing what these parts look like when pulled apart should make things much easier for you. Not knowing exactly what I was looking for and at made me waste time playing around with things until I figured things out. How about a shot of the tumbler assembly once it is removed from the fuel cap?
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The larger latch/hook at the very end of the tumbler is the one you have to push down into the tumbler to remove it. Note that when the key that fits into the lock is inserted ALMOST all the way into the tumbler this latch will want to stay in place within the tumbler. That is the key (no pun) for you to get this tumbler out easily. If you push the key all the way into the tumbler like how you do it when you want to unlock the lock that last locking latch will not push into the tumbler. The knobbed end of the key will take up all the room that latch needs to be able to be pushed into it’s slot in the tumbler. How far out does the key need to be in order for you to push this latch into the tumbler? Almost all the way in. I found that if you push the key all the way in & slowly pull it back out you can actually feel & hear that latch snap back a little bit as you pull the key back. So the trick is to pull the key back out slowly until you feel that first click. That’s the position it needs to be at in order for you to pull the tumbler out. Here’s a picture of the cylinder in the fuel cap the tumbler slides into:
And here’s a better image of the tumbler mounted inside that fuel cap cylinder with a good view of the copper colored latch holding it in position down in the lower right side of that cylinder.
End of part one