Replacing Saddlebag Locks

[MCML]

I now have a pretty good understanding of the dollar value of the damage caused to my FJR on Tioga Pass last month. Both my local dealer (Woodland Hills, CA) and Gary at University have been very helpful. One question does remain however. The lock in the bag was damaged by the force of the bag being ripped off the bike and it needs to be replaced. No one, however, seems to know the procedure for obtaining a keyed-alike relacement or having a new lock rekeyed at a locksmith. Also, it seems that you have to buy a full set of locks (two or three, it's not clear) from Yamaha and that you cannot buy a single lock. Since I use a Givi topbox I do have the spare Yamaha lock "in reserve." However, it is clearly not my responsibility to solve problems for the other guy's insurance carrier. Their job is to make me whole. If anyone has been down this road and knows the best way to replace one lock while ensuring that the bike has three "luggage" locks all keyed to match the ignition switch please let me know. Thanks.

 

[twowheelnut]

MCML, I recall, vaguely, that the keyed alike locks come only with the ignition set. If you may recall, my top triple tree clamp snapped when changing out the springs. I made the inquiry to the tech about what happens if they break the ignition when doing the swap. He made the inquiry of Cypress and the answer he got was that keyed alikes are sold as sets only. I bet they ain't cheap, either. Can they remove the cylinder and put it in a new housing or is that shot too?

 

[ian]

I copied this off another board (dare I say EZ?) Hope it helps, I haven't tried it. Ian, Iowa

Adapting old key to new lock.

1. Remove lock from recently purchased luggage with lock that doesn’t match your current key. (Important - mark as 'New Lock')

2. Remove lock from one of the existing side luggage cases and mark as "Existing Lock".

Note: To be able to remove lock from the luggage you must remove the metal arm from the back of the locks first. Since I did not have the 'Security Torque Bit' to remove the screws I used a pair of plies on the side of the screws and they twisted right up.

3. Once both locks are pulled from the luggage and labeled, insert the key into the lock and push the lock from the back and it will pop out of the black metal casing that it sits in. You may have to wiggle the key a bit.

4. Take a piece of paper and label New Lock and Existing lock and replicate the tumblers positioning under each label. For example I have 3 short horizontal stacked dashes on the left and then 2 stacked on the right. What this allows you to do is when you pull the tumblers from the lock with a pair of needle nose pliers you place them next to the schematic of the lock so you don't lose the sequence of the tumblers.

5. Once you have created two identical schematics with different labels (New and Existing) pull the tumblers from each and place physically on top of the respective schematic.

6. You will notice very quickly the bottom of each tumbler differs in height. This is what allows the lock to unlock or not to unlock. You want to take the 'New Lock' tumblers and change the sequence so it most closely matches the thickness sequence of the "Existing Lock" tumblers which are laid out on the same paper.

7. Once you re-sequence the tumblers in the "New Lock" try placing them back into the "New Lock" and see if when the key is inserted all tumblers are flush. If you need an example of what I talking about stick the key in the "Existing Lock" and you will see how flush the tumblers are.

8. Now since I can almost guarantee you that not all 5 re-sequenced tumblers in the "New Lock" are flush when the key is inserted you may need to reshuffle again. What I found is that after reshuffling a few times there were 2 tumblers that were too small and would never be flush, so I left them out. That is correct I am only using 3 tumblers.

9. To use all 5 tumblers you can either grind down the new tumblers if they are too thick or possibly use Liquid Steel to fill in and then grind down to spec to match the tumblers in the "Existing Lock"

10. Once the "New Lock" tumblers are flush place back in the metal casing. There is a little nipple on the back of the lock. If you can’t remember if it was at the top or the bottom, you will learn real quickly, because the metal arm has a mating notch that only works one way.

PLEASE be careful of the little springs under the tumblers, THEY ARE EASY TO LOSE when you are pulling the tumblers with the needle nose pliers!!!

Hope this has not been too confusing and good luck. It was pretty easy. Also on the Yamaha OEM rear trunk I removed the Handle assembly first before I removed the lock. Not sure if you have to. Ryan