[stealth210]

For some reason I thought the bolts were the same when removing the fuel cap bolts. There are 3 that are the same and the with the remaining two: they are different. Does anyone know what the pattern is for re-installation?

Here's what I'm looking at (allen bolts):

|-----
|-----
|-----
|=== (thicker thread than the above three)
|==

I'm not sure which one fits in which hole. The bolts make a star pattern if you are looking directly down on them from above the tank.

Any help would be much appreciated!

Thanks

 

[VARIABLE9]

If you took all 5 out already, you should be able to lift out the fuel cap assy and look at which have the longer threaded inserts. I am guessing long in front (x1) and in back center (x2) but I dont have my SV near me to validate this.

 

[stealth210]

If you took all 5 out already, you should be able to lift out the fuel cap assy and look at which have the longer threaded inserts. I am guessing long in front (x1) and in back center (x2) but I dont have my SV near me to validate this.

Thanks, but I'm trying to recover from a lost key situation and cannot get the whole thing out. I was going to try to see if the key code was imprinted on the cap somewhere on the bottom (I had read a thread about lost keys and saw that it might be printed there), but since I cannot remove it that doesn't seem to be an option. So, I just wanted to reassemble it.

 

[VARIABLE9]

Ahh, drill it out might be best option but I do think my pattern is correct.

 

[Lost1888]

If you place the shorter ones in the wrong hole won't the just drop in flush? Then take them out and put the longer one in and the shorter ones in the other holes.??? I would imagine if you put all the screws in the right holes they would be sitting at the same height unscrewed all the way around.


I'm bored so I will go out and look for you. You lucky bas****

 

[Lost1888]

2 and 10 o-clock are short

1,5,7 o-clock are long

 

[VARIABLE9]

2 and 10 o-clock are short

1,5,7 o-clock are long

What if you are looking at it from the front?

 

[stealth210]

Ahh, drill it out might be best option but I do think my pattern is correct.

Thanks, that was the pattern.

Now I guess I'll try to pull the ignition assembly and see what a locksmith can do. I'm dreading the inevitable which is that they can't pick it to find the sequence of the cut. ~$200ish down the drain on a new lock set. I should have had a couple sets made when I bought it used last summer while receiving only one key. My mental excuse was 'I have never lost a set of keys in my life', so it took a low priority.

 

[VARIABLE9]

Thanks, that was the pattern.

Now I guess I'll try to pull the ignition assembly and see what a locksmith can do. I'm dreading the inevitable which is that they can't pick it to find the sequence of the cut. ~$200ish down the drain on a new lock set. I should have had a couple sets made when I bought it used last summer while receiving only one key. My mental excuse was 'I have never lost a set of keys in my life', so it took a low priority.

I have heard that if you can get the blank a good smithy can cut the key.

 

[Lost1888]

What if you are looking at it from the front?

Then your weird! Everything you explain should be explained as if you were sitting on the bike.

You are one funny guy.;D

 

[stealth210]

Then your weird! Everything you explain should be explained as if you were sitting on the bike.

You are one funny guy.;D

Haha, Thanks to the both of you. Just FYI, I have 5 bolts total (obviously), 3 are a certain size the last two are thicker threads but one is shorter than the other. Either way, I took a 50/50 and guessed correctly. I think I put the shorter one at the 2 o'clock and the other at 10.

Now, big question. What size are the ignition bolts? I'm thinking T40S; does this sound right or should I post a new thread?

Thanks again

 

[VARIABLE9]

Haha, Thanks to the both of you. Just FYI, I have 5 bolts total (obviously), 3 are a certain size the last two are thicker threads but one is shorter than the other. Either way, I took a 50/50 and guessed correctly. I think I put the shorter one at the 2 o'clock and the other at 10.

Now, big question. What size are the ignition bolts? I'm thinking T40S; does this sound right or should I post a new thread?

Thanks again

Not sure but they are 'security' Torx bolts, set of Lisle STorx from pepBoys was $18.

 

[stealth210]

Not sure but they are 'security' Torx bolts, set of Lisle STorx from pepBoys was $18.

Just a quick follow up; I'm back on the road with new keys. Can I get a suzuki dealership to cut a new OEM key with a copy? The new keys work, I just like the look of the stock one although I know I'm being obsessive with that.

Here's what I went through:
1) Located a secure torx 40 - $7
2) Removed front fairing and all associated bits
3) Removed ignition
4) Discovered the wire is buried deep within
5) Lifted tank, requiring removal of seat
6) Removed radiator
7) Tried to remove the inner plastic piece that covers electrical connectos, driver's side plastic bulge screw refused to come out.
8 ) Pulled down plastic wire cover far enough to remove ignition wire
9) Paid about $45 to have locksmith re-key ignition with 3 non-stock keys
10) Reassembled everything and rode around a bit

Not bad considering I was facing paying $225 to suzuki for a new lock set.

 

[tcl]

9) Paid about $45 to have locksmith re-key ignition with 3 non-stock keys

You mean he just made keys based on the ignition and not that he completely re-keyed keyed the ignition such that the original key wouldn't fit, right?

EDIT: because otherwise in less then 150 miles you'll be back there.

 

[Lost1888]

You got it done with a little money spent. Good Good.


Now don't loose all your keys!:nana:

 

[stealth210]

You mean he just made keys based on the ignition and not that he completely re-keyed keyed the ignition such that the original key wouldn't fit, right?

EDIT: because otherwise in less then 150 miles you'll be back there.

Ahh yes, it's keyed based off the original pattern. That was the first thing I checked when I got home. ;D

 

[VARIABLE9]

I would try somewhere like d2 Cycles or eBay and simply buy a used OEM lockset from a part out.