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Old 04-07-15, 04:49 PM   #1
Bibio
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Thumbs up Ignition key wiggle solved

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.
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Old 06-07-15, 11:38 AM   #2
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Default Re: Ignition key wiggle solved

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
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Old 06-07-15, 12:09 PM   #3
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Default Re: Ignition key wiggle solved

Don't suppose you got photos of the process?
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Old 06-07-15, 03:08 PM   #4
650
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Default Re: Ignition key wiggle solved

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!
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Old 06-07-15, 03:15 PM   #5
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Default Re: Ignition key wiggle solved

i'll take some pics later for a 'how to'
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Old 06-07-15, 08:45 PM   #6
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Default Re: Ignition key wiggle solved

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.



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



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



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
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Old 06-07-15, 09:13 PM   #7
DarrenSV650S
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Default Re: Ignition key wiggle solved

You forgot about the really fun bit. Unplugging the connector

Good work though! My key was really bad too
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Old 06-07-15, 09:14 PM   #8
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Default Re: Ignition key wiggle solved

Sweet, thanks for that!!
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Old 06-07-15, 09:59 PM   #9
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Default Re: Ignition key wiggle solved

Quote:
Originally Posted by DarrenSV650S View Post
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.
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Old 07-07-15, 08:34 PM   #10
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Default Ignition key wiggle solved

Is there no end to your genius Bib!?
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