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Old 10-23-2014, 05:44 AM   #1
1994klr250 OP
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How to open klr650 gas tank cap with no key?

One of my friends has klr650 with a newer gas tank on it. He lost the keys for the bike, but it turns out the ignition switch key from my klr250 works in his ignition. So he can start the bike now, but the gas tank has a different key since it was a replacement tank off of a newer klr. Does any one have an idea how to open or get a new key for the gas tank cap?
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Old 10-23-2014, 06:45 AM   #2
AlpinaE24
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Use a 2" hole saw and blast a new fill hole
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Old 10-23-2014, 08:33 AM   #3
1994klr250 OP
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I'm looking for a less destructive way than that.
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2300 miles on a 250 all for a sticker http://www.advrider.com/forums/showthread.php?t=616239
Fall ride on a KLR250 http://www.advrider.com/forums/showthread.php?t=754065

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Old 10-23-2014, 11:34 AM   #4
Beezer
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I'd take it to a locksmith. maybe take the tank off the bike if you have to.

I've heard that the key code is stamped on the bottom of the helmet lock.... I've seen the number but haven't checked that it's true. it would be good for the original ignition & tank only though

klr's have 2 key cross sections that are mirror image. one is more rare & hard to find. moral to the story is keep at least one spare in a safe place
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Old 10-23-2014, 11:51 AM   #5
1994klr250 OP
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Thanks for the information. I couldn't believe when the key to my 250 worked on his 650. I have more than a few spare keys for my bikes, but he didn't. I ended up giving him a spare key so he can at least start it now.
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2300 miles on a 250 all for a sticker http://www.advrider.com/forums/showthread.php?t=616239
Fall ride on a KLR250 http://www.advrider.com/forums/showthread.php?t=754065

1994 KLR250, 2009 F800GS, 2006 KLX351
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Old 10-23-2014, 12:45 PM   #6
Stretch67
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Quote:
Originally Posted by 1994klr250 View Post
Thanks for the information. I couldn't believe when the key to my 250 worked on his 650. I have more than a few spare keys for my bikes, but he didn't. I ended up giving him a spare key so he can at least start it now.
There are only a certain number of possible combinations of pin placement within a lock,so if that manufacturer has a high production number, odds are there are several identical keys out there...

In '88 I bought a 1967 Mustang from the original owner in Hawaii.

Six years later I bought a '78 Ford truck from a friend in Georgia....

Both vehicles have the same ignition and door locks.
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Old 10-23-2014, 01:35 PM   #7
RFVC600R
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I had a lock smith make me a key for a Vespa, xl250r and a DT50. Just bring the tank to a smithy
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Old 10-23-2014, 02:52 PM   #8
GoneBallistic
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LockSmith or LockPick

I'd take it to a smith. If you have to, you can probably back fill the tank through the carb to tank line, it'll just take some time.

a locksmith can pick the lock and make you a key for probably less than 50 bucks.


or you can get a cheap lock pick set from Amazon and go to town. With a pick set, a half hour on youtube, and an hour of messing around with it, he'll be in. Picking that lock isn't going to be that hard.

you could also probably just carefully drill it out, or get a strong flat blade screw driver and just force it, then replace the lock with a new one, or a non-keyed tank.
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