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Offline Iain

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Replacing top box lock barrel
« on: March 08, 2015, 05:10:58 pm »
When I bought my Trophy I already had my top box from my previous Sprint GT. Now I wanted to change the barrel so I wouldn't have to carry another key but the dealer said this couldn't be done without damaging the box. I'm tempted to drill out the barrel and try and remove it. Has anyone done this? Has anyone being able to extract the barrel without damaging the box?
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Offline Gordon3xBBB

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Re: Replacing top box lock barrel
« Reply #1 on: March 08, 2015, 05:32:42 pm »
I SO want to do this too - but I've been reliably informed that the Top Box will be "destroyed" in the attempt...

Perhaps when I have a little more spare time I'll check what's involved...
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Offline Coconut

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Re: Replacing top box lock barrel
« Reply #2 on: March 08, 2015, 06:35:45 pm »
From researching this .....

It IS possible to remove a lock barrel from the Top Box ( and Panniers ) without causing damage  :152:

The lock barrel has an extra 7th "pin" at the end, just beyond the reach of the key
which clicks into place under spring pressure when it is first inserted into the housing,
and holds the barrrel in place.
( The first 6 "pins" are the locking pins that are operated by the key
to allow the lock barrel to rotate in the housing ).

To remove the lock requires this end pin to be depressed using a special Locksmith type tool,
which will then allow the barrel to be withdrawn.

The tool is inserted into the keyhole to the depth of the retaining pin,
and then rotated 90 degress to depress the pin, allowing the barrel to be withdrawn.

The tool can be manufactured from a 2mm Allen key,
with the right angled end ground down to a specific length,
which appears to be 3.6mm total, or 1.25mm away from the shoulder of the Allen key.

Photo of a home made tool attached ( for registered Forum Members logged on )
courtesy of our friends over on the Tiger 800 Forum  :028:




« Last Edit: September 10, 2020, 04:30:36 pm by Coconut »

Offline LPBeck

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Re: Replacing top box lock barrel
« Reply #3 on: February 24, 2016, 09:00:07 pm »
Thanks Coconut! I've asked my local dealer to no avail, so I really appreciate your input.  :062:

Thanks again,
Larry

Offline Iain

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Re: Replacing top box lock barrel
« Reply #4 on: February 25, 2016, 08:39:53 am »
afraid I never succeed with this..tried with the modified allen key as shown but no luck.. :187:
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Offline gtgt2112

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Re: Replacing top box lock barrel
« Reply #5 on: February 25, 2016, 09:45:09 am »
How about taking the bike and topbox to a locksmith, if they are friendly enough it should not cost too much

Offline Iain

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Re: Replacing top box lock barrel
« Reply #6 on: February 25, 2016, 09:54:33 am »
Yeah tried that, no luck again!
Given that I'm keeping the bike long term I've been debating getting a new box (my existing came from my previous Sprint GT hence the different barrel) since I've got the barrel that came with the Trophy. Having 2 keys is annoying!
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Offline azgman

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Re: Replacing top box lock barrel
« Reply #7 on: February 25, 2016, 01:52:34 pm »
The BMW top case has a similar design, but there is an access panel on the top lip of the top case (bottom half when open). You insert the "locksmith" tool into this recess to depress the "7th pin" of the barrel and then you insert the key and turn it to remove the barrel. A good locksmith should be able to remove the barrel for you. Let us know if you get this done properly!

Tiger 800 forum link on topic
« Last Edit: February 25, 2016, 02:15:29 pm by azgman »
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