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post #1 of 8 (permalink) Old 9-16-2019, 3:54 PM Thread Starter
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Hello everyone, my name is Shawn. I used to ride dirt bike a lot when I wasin my 20's. Just bought a 1989 EX500 for a winter project. Seems to be a lot of useful information on here as well as a lot of smart seasons riders. Looking forward to digging into this bike to get ready for next season. Pictures coming soon. First order of business will be removing gas cap. There is no key. Any tips on doing that? Thanks!
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post #2 of 8 (permalink) Old 9-16-2019, 7:41 PM
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Removing the cap with out the key may be tricky.


There is a screw you need to access with the cap open. You will probably end up needing to blindly drill the screw out. May be able to get some measurements to hit the target on the head. Before doing any drilling you should just remove the hex screws to make sure the screw is still in place.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #3 of 8 (permalink) Old 9-16-2019, 8:02 PM Thread Starter
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yeah, I figured it was going to be a tricky fix. Thank you for the picture man! I will remove those screws to check if screw is in place. From your picture I believe I can get pretty close, or at least close enough to get it out. Thanks again man!
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post #4 of 8 (permalink) Old 9-16-2019, 8:39 PM
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Welcome to the forum, HaweyeVAW120!
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post #5 of 8 (permalink) Old 9-17-2019, 4:23 AM
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Another alternative would be to remove the helmet lock. There you should find a key code number that a locksmith could make a key that would open the cap. Assuming it is the original cap. It would also fit the ignition, if that is original and you don't have a key for that either.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #6 of 8 (permalink) Old 9-17-2019, 3:50 PM
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Quote:
Originally Posted by bpe View Post
Another alternative would be to remove the helmet lock. There you should find a key code number that a locksmith could make a key that would open the cap. Assuming it is the original cap. It would also fit the ignition, if that is original and you don't have a key for that either.
+1, cheaper then a new/used gas tank.

1993 Teal/White EX500 6K First Street Bike
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post #7 of 8 (permalink) Old 9-18-2019, 8:44 PM Thread Starter
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Thanks! Plan on starting work on the bike in a couple of weeks. First get the cap off and replace with new, flush fuel system, then do a carbs clean and rebuild kits, change fluids, plugs, filters. Get it runnin like a champ. Then comes the fun stuff
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Last edited by HaweyeVAW120; 9-18-2019 at 8:54 PM.
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post #8 of 8 (permalink) Old 9-23-2019, 3:07 PM
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Quote:
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Another alternative would be to remove the helmet lock. There you should find a key code number that a locksmith could make a key that would open the cap. Assuming it is the original cap. It would also fit the ignition, if that is original and you don't have a key for that either.
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+1, cheaper then a new/used gas tank.
Yeah, that's what I did on bike-in-boxes EX250 I got without key. Cost me $50 for 2x brand-new master keys made from key-code. Worked perfectly and I keep 2nd one in safe just in case.
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