Help replacing the key tumbler set in the gas cap - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 15 Old 07-04-2013, 11:01 AM Thread Starter
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Help replacing the key tumbler set in the gas cap

First off, a Happy 4th to ya'll.

I am working on a fella's 2007 KLR that has a bum ignition switch, so it's being replaced. Since the key set is also used for the helmet lock and gas cap, those need to be swapped out.

Helmet lock has been replaced, but am running into a problem with the new tumbler set for the gas cap. I would have thought that once the cap was disassembled the old tumbler set would easily pop right out. That's not the case.

Any words of wisdom for getting out the old tumbler set so I can get the new one in?

TIA
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post #2 of 15 Old 07-04-2013, 11:41 AM
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If you have the cylinder in your hand stick new key in the tumblers that stick out past the cylinder lightly file flush.......there is a spring loader pin you depress to remove cylinder( don't file it ..it acts as a keeper for the cylinder)

take your time and don't loose the tiny
springs
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post #3 of 15 Old 07-04-2013, 12:14 PM Thread Starter
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Originally Posted by kwoody101 View Post
If you have the cylinder in your hand stick new key in the tumblers that stick out past the cylinder lightly file flush.......there is a spring loader pin you depress to remove cylinder( don't file it ..it acts as a keeper for the cylinder)

take your time and don't loose the tiny
springs
Appreciate it, but that's what I'm looking for.... that "magic" pin you depress to get the old tumbler set out.
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post #4 of 15 Old 07-04-2013, 12:23 PM
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it's on the end spring loaded only goes down far enough to let cylinder come out
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post #5 of 15 Old 07-04-2013, 12:35 PM
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Not specifically what you're looking for, but this may help: repairing the vent seals

T

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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #6 of 15 Old 07-04-2013, 12:43 PM Thread Starter
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Originally Posted by kwoody101 View Post
it's on the end spring loaded only goes down far enough to let cylinder come out
Admittedly, I can be as thick as a brick sometimes, but I swear I can see nothing of a depress-able pin, or access to one.

What I am seeing:......

Never mind. Fookin' site won't allow me to post to my smugmug pages. :-(
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post #7 of 15 Old 07-04-2013, 12:47 PM Thread Starter
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Originally Posted by gbyoung View Post
Admittedly, I can be as thick as a brick sometimes, but I swear I can see nothing of a depress-able pin, or access to one.

What I am seeing:......

Never mind. Fookin' site won't allow me to post to my smugmug pages. :-(
Smugmug link sent via PM.

Really appreciate your trying to help.

Guy
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post #8 of 15 Old 07-04-2013, 02:05 PM
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Look at the vent seal repair it shows how to get the lock cylinder out Thanks Tom for finding it
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post #9 of 15 Old 07-05-2013, 08:52 AM Thread Starter
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Success!

Much thanks to Kwoody and Tom for pointing out the vent repair link with pictures put up by Jeff Saline.

Coincidentally, I had the pleasure of meeting Jeff in 2006 up in Hill City, SD when I was up there for a COG Rally..... on my KLR. Had full intentions of trying to complete the GDR that went awry the year before when I broke my collarbone up in MT. Jeff wisely talked me out of it and pointed out some nice forest roads in and around Hill City.
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post #10 of 15 Old 07-05-2013, 09:32 AM
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I've never had the pleasure of meeting him, but my impression has long been that he's good people.

T

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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