TZR250 3XV fuel tank question

[SoCal250]

Can the fuel cap assembly be removed by taking out the 7 bolts (#10 & #11) with the cap locked, or does the cap need to be unlocked?
My lock will not open and I couldn't get the cap to come loose even with the small bolts all removed.

[elliottles1]

Socal250

working from memory of other similar yamaha strokers that have a very similar fuel cap, there is ONE small allen bolt under the locked part of the fuel cap! it screws into the dropped section of the opening near where the breather pipe exits.

i drilled the lock off of mine and bought a replica (very good one) from china on ebay, but of course you end up with non matching keys.

hope that helps
les.

[elliottles1]

me again

here is a replica, in the 4th pic. you can see a small allen screw and the mounting hole is near the hinge part of the cap.

les.

https://www.ebay.co.uk/itm/184829670056?hash=item2b08b4f2a8:g:JrUAAOSwY09hgnuu&amdata=enc%3AAQAIAAAA4GZxeUeg07zF2BcCSUvu0zhabGwYeRvN1PCy77Pfz%2BGHScXZvkCrIxwdsLVUbYtv2hdVPBq4RX%2Bk7gfWzZQvUxnrB0qCMnHArNULZe06MkW50Bmz%2FhE702yygCnet0Rq6Sl2q6dLbg7XcCEysXwSm1q6YCsI6OsBcRhJY3E881EgkVDdy3Bb3zfgc5ddlaGhEYYnlBLoLOC8gjYmALM1xp4M7zu2bp2w7gEiBaPSZlNrU1dPwn61laZNCIYt7q4ZmlzM8UELINEWGvM5sQMokuLmjvRyhVEhdwmOx38mrT2O%7Ctkp%3ABFBM9Puvg6Ji

[SoCal250]

working from memory of other similar yamaha strokers that have a very similar fuel cap, there is ONE small allen bolt under the locked part of the fuel cap! it screws into the dropped section of the opening near where the breather pipe exits.

Doh! That's what I was afraid of.

Thanks Les! After your first post I searched around on Ebay for photos of one opened and found this one, which shows the little screw under the cap. https://i.ebayimg.com/images/g/btsAAOSwMexiLwHX/s-l1600.jpg
I really don't want to drill mine. I'm under a time crunch to get this running and need a functioning cap so there's no time to order a new one, and I really don't want to lose my current matching locks.

I'll keep working at it and see what I can make happen.

[elliottles1]

socal250,

guaging where that screw is in relation to the visible ones, i bet you could drill a hole just big enough to get an allen key thru there and have at it.

not much to lose!

cheers
les.

[elliottles1]

Yup,  just checked on one of  mine. 45 degrees in and forward of the allen screw that is at about 4 or 5 oclock drill a 5mm hole 15mm away from said screw centre. that is, a hole thru the opening part of the fuel cap. the offending screw will be there (hopefully!).

les.

[SoCal250]

Yup,  just checked on one of  mine. 45 degrees in and forward of the allen screw that is at about 4 or 5 oclock drill a 5mm hole 15mm away from said screw centre. that is, a hole thru the opening part of the fuel cap. the offending screw will be there (hopefully!).

Les,
I think I'm going to give this a try. Does this look about right?


With this method I should be able to preserve the lockset so I can transfer it to another OEM cap later on.

Here's what I could see from the inside from the petcock hole.

[elliottles1]

socal250,

that to me looks spot on angle wise, i measured 15mm center to center of the bolts. its a small allen key, a 5mm hole would give you wiggle room, but you could start smaller and see if you are on or not. in my estimation you should miss any internals of the fuel cap.

no need to change the lock if you get one of these!!!;-

https://www.ebay.co.uk/itm/334008279666?hash=item4dc471e272:g:gD0AAOSwP61gpx88&amdata=enc%3AAQAIAAAAwIfziARVmCh6O3xoEmsEryrfuwD9pJlRLFRcUESU1aAF5TtIbcC16Wcjg5AAq3Nen%2F4LTh38iAvclQeiqbrqS90u9WhyH4xX8TpMh3tR4EZ71dsfLpM%2BCvotNHS7RpmOM45TNHpe%2FmBn9LuWX3YTYr4IAGVnua1zk30V44rjFyXoEwQZhRvAOuwD3Dybkj%2BZo5YBPYVHolosVsd5%2BQxvSNc7cy4LXnPIuY%2Bu7cSS5sw8h%2FzMJb9iV%2Fa2Z4IIxPb46w%3D%3D%7Ctkp%3ABk9SR6zO39aiYg

let me know how it goes!
les.

[so-cal-sdr200]

Russ. Can you get to the two Phillips head screws through the petcock hole?
 The picture you took using the borescope makes it look possible with a long
 screwdriver.
 Drop the lock lever away from the cap assembly.
 Just a thought.
 Cheers, Jeff

[SoCal250]

Can you get to the two Phillips head screws through the petcock hole?
 The picture you took using the borescope makes it look possible with a long
 screwdriver.
 Drop the lock lever away from the cap assembly.

I'll give it a shot today before breaking out the drill. It's a long reach to get the the visible screw and I don't think I'll be able to access the other one due to the angle, since the petcock hole is over on the left side of the tank. We'll see though.

I've had PB Blaster soaking in the lock for 2 days now. It would be a miracle if it suddenly just decided to turn , but I think that's a big ask.

[SoCal250]

socal250,

that to me looks spot on angle wise, i measured 15mm center to center of the bolts. its a small allen key, a 5mm hole would give you wiggle room, but you could start smaller and see if you are on or not. in my estimation you should miss any internals of the fuel cap.

no need to change the lock if you get one of these!!!;-

https://www.ebay.co.uk/itm/334008279666?hash=item4dc471e272:g:gD0AAOSwP61gpx88&amdata=enc%3AAQAIAAAAwIfziARVmCh6O3xoEmsEryrfuwD9pJlRLFRcUESU1aAF5TtIbcC16Wcjg5AAq3Nen%2F4LTh38iAvclQeiqbrqS90u9WhyH4xX8TpMh3tR4EZ71dsfLpM%2BCvotNHS7RpmOM45TNHpe%2FmBn9LuWX3YTYr4IAGVnua1zk30V44rjFyXoEwQZhRvAOuwD3Dybkj%2BZo5YBPYVHolosVsd5%2BQxvSNc7cy4LXnPIuY%2Bu7cSS5sw8h%2FzMJb9iV%2Fa2Z4IIxPb46w%3D%3D%7Ctkp%3ABk9SR6zO39aiYg

let me know how it goes!
les.

Thanks Les! I'll report back on the outcome

[rodneya]

Look for a key code under the little flap. I got a key for a suzuki cap that way

[SoCal250]

Look for a key code under the little flap. I got a key for a suzuki cap that way

I have the key. The lock is frozen.

[SoCal250]

socal250,

that to me looks spot on angle wise, i measured 15mm center to center of the bolts. its a small allen key, a 5mm hole would give you wiggle room, but you could start smaller and see if you are on or not. in my estimation you should miss any internals of the fuel cap.

no need to change the lock if you get one of these!!!;-

https://www.ebay.co.uk/itm/334008279666?hash=item4dc471e272:g:gD0AAOSwP61gpx88&amdata=enc%3AAQAIAAAAwIfziARVmCh6O3xoEmsEryrfuwD9pJlRLFRcUESU1aAF5TtIbcC16Wcjg5AAq3Nen%2F4LTh38iAvclQeiqbrqS90u9WhyH4xX8TpMh3tR4EZ71dsfLpM%2BCvotNHS7RpmOM45TNHpe%2FmBn9LuWX3YTYr4IAGVnua1zk30V44rjFyXoEwQZhRvAOuwD3Dybkj%2BZo5YBPYVHolosVsd5%2BQxvSNc7cy4LXnPIuY%2Bu7cSS5sw8h%2FzMJb9iV%2Fa2Z4IIxPb46w%3D%3D%7Ctkp%3ABk9SR6zO39aiYg

let me know how it goes!
les.

Thanks Les! I'll report back on the outcome

Well the drilling was successful. I marked the spot on the cap with a Sharpie and then centerpunched it. Drilled a small hole to peek in and then a larger hole to allow the Allen key through. It was nearly a direct hit. The screw was unthreaded with ease! 

The only drawback was that the latch was still holding the cap into the tank so I was forced to drill the lock. No way around it.

In any event, it's out now and I modified the lock barrel so it works with a screwdriver and the cap can be latched and unlatched. It's only temporary.
Thanks for your help and measurements!

[elliottles1]

socal250

what a shame you had to drill the lock, i thought that the whole yoke would have lifted up enough at the rear to allow the lock to disengage, wrong again!

cheers
les.