Ignition key wiggle solved

[Bibio]

i got a new lockset for the bike as the old OEM one was doing my nut it having to wiggle the key to get the bike started and the steering lock would not turn.

so i thought what the hell i might as well have a look at the OEM one to see what's up with it. turns out the key/lock has worn.

solution could be one of two things. 1. get a new key cut slightly oversized. 2. file the pins down.

i opted to file the pins down as it was an experiment and i'm glad to say it worked a treat.

the hardest part of this would be getting the ignition off the yoke as it has security torx bits which are threadlocked in, getting the correct bit goes a long way to dealing with this though.

once the lock is off then its a simple case of undoing the two small screws, lifting the cap off, inserting the key then lifting the barrel out. once the barrel is out you can file the pins that have a high point or just take the file across the whole lot of them like i did (dont take off more than you need to). next is to check that the barrel turns as it should so put the barrel back in with the cap (dont bother with the screws) hold it down then turn the key, if the key turns without any problems then its fixed if not take more off the pins on the barrel and repeat till is all good.

[Ratty]

Good post. I may try this soon on the thou. Key only works one way and it's getting proper hard to turn now. Need a waggle.

Thanks Alan

[Redmist]

Don't suppose you got photos of the process?

[650]

Not like Suzuki to use cheap, cheese like metals on things is it! I've owned two SV's and they both did exactly this, irritating as hell when you want to put the steering lock on and you can't undo it!

[Bibio]

i'll take some pics later for a 'how to'

[Bibio]

The special tools you will need:
T40 Security bit (halfords sell these)
a good JIS screwdriver (the cheep orange handled philips screwdrivers from B&Q fit fairly well)
A file (preferably a fine one)(do not use a dremel as you will take far too much off)

WARNING...DON NOT ATTEMPT TO TAKE THE IGNITION OFF THE YOKE WITHOUT THE SPECIAL TORX BIT.. YOU HAVE BEEN WARNED

the ignition switch connector is a PITA to get at on the SV so i would recommend to do this in situ.

remove the yoke, turn the yoke upside down and place back on the forks, use the T40 bit to remove the ignition.
once the ignition is off the yokes you then remove the two small screws that hold the cap on.

http://s4.postimg.org/4q8maysbh/screws.jpg

remove the cap and ignition barrel with the key (there is a spring inside so be careful)

http://s3.postimg.org/j4pbon1df/barrel.jpg

with the key still in the barrel clean the barrel using some WD40 and a rag then take a file and file down the high points on the pins using an arc motion

http://s11.postimg.org/yakkm4l0j/pins.jpg

once you have filed down the high points its a case of testing and taking off more with the file till the ignition rotates freely.

installation is reversal of removal.

Lance

[DarrenSV650S]

You forgot about the really fun bit. Unplugging the connector ;)

Good work though! My key was really bad too

[Redmist]

Sweet, thanks for that!!

[Bibio]

You forgot about the really fun bit. Unplugging the connector ;)

Good work though! My key was really bad too
thats why i said in situ. one of the very first things i done to the bike when i got it and the front end was off was to remove the silly bar that holds all the front connectors on just in case i ever got a problem with the dreaded green connector or switchgear.

[PyroUK]

Is there no end to your genius Bib!?

[Bibio]

Is there no end to your genius Bib!?

its not genius its being tight fisted that helps :smt023

[PyroUK]

Hahaha!!

[Alexander94]

Thanks for that Bibio! Mine's been a real pain recently so I'll have to get some fine files and give it a go (i already have a decent set of security bits)

I've not had any trouble with the connector though, mine's a curvy so is the pointy connector worse?

[ScottishRawker]

guy who sold me the thou explained the key wiggle,
so i've glad there is an easy fix,

will do this and the tps hopefully thursday!

[Bibio]

yes the early pointy ones like to burn one of the terminals. not heard of any of the twin spark ones doing it so far.

just get yourself a fine engineers file and tbh you could use wet'n'dry with a block on the back. the pins are brass and soft as shizz.

[ScottishRawker]

I've got some diamond files that i use for de-tuning snowboard edges so will use them!

[Bibio]

yup they should be perfect, just dont go mad.

[Corny Gizmo]

Bibio, The day after you post this my 16 month old bike has started with ignition problems.

I have to angle (pull) the key down toward the tank and then turn it on.

Is this the same issue? if so what file would I need to sort it?

[Bibio]

thats the exact problem



just get yourself a fine engineers file and tbh you could use wet'n'dry with a block on the back. the pins are brass and soft as shizz.

[Corny Gizmo]

Cheers Bibs!

I dont suppose suzuki would replace it under warranty? its only 16 months old

[Bibio]

no harm in asking your local suzuki dealer.

[gt900uk]

This may be a case of corrosion inside for some people. Mine was doing it, needed a good waggle and even got to the point I couldn't turn the key. Decided I better do something about it. Liberal does of acf50 in the lock and 5 minutes of turning sorted it and it's been fine ever since. I just give it a wee acf50 when going over the bike now.