Removing Ignition Switch

Biggar81 · L Plate Warrior Joined: 08 Apr 2014 Karma :

I have a 2001 Kawasaki 500r. i just recently got the bike, and within the first day of really riding it the key broke off in the ignition -_-... the key just so happened to break with it in the lock position which seems to have made the key impossible to get out. I have taken it to a locksmith and they have even said that they couldn't get it out, the only way to do it would be to take the ignition off, take it apart, and get the other piece of the key so they could make a new copy. Really dont want to take this into a shop to get it done and spend a boat load of money. Could someone please explain to me the steps on how to remove the ignition from the bike myself?

1198 · World Chat Champion Joined: 24 Jan 2013 Karma :

The barrel is probably secured to the top yoke from below. If so you'll need to secure the bike so there's no weight on the front forks / yokes, then you loosen and remove the main headstock bolt (the one through the headstock), loosen the top folk clamps then carefully lift off the top yoke and invert it. (Care with brake and clutch fluid). That should give you access to the bolts that hold the barrel on. Oh, they'll be security bolts too most likely!

davebike · World Chat Champion Joined: 15 Nov 2013 Karma :

Biggar81 · L Plate Warrior Joined: 08 Apr 2014 Karma :

Once I get done with all of that, (or at least attempt to), how to i go about taking the actual ignition apart, getting the key out and putting it back together?

davebike · World Chat Champion Joined: 15 Nov 2013 Karma :

You may be able to strip it yourself but it isn't easy !
If you do take great care to put all the bit back and where they came from

Me I am professional bike mechanic I take it to a good locksmith or get another lock
I striped a few not easy /fun

Dave
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Dave
NC750Xdct + others at work !
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P. · Red Rocket Joined: 14 Feb 2008 Karma :

Do you have a spare key? Assume not otherwise you'd be able to get an easy copy Laughing

I tend to find its cheaper buying a new ignition, but then you have the seat lock and petrol cap to worry about...

Biggar81 · L Plate Warrior Joined: 08 Apr 2014 Karma :

davebike · World Chat Champion Joined: 15 Nov 2013 Karma :

Yes
Bike on stand either main or workshop Front wheel and forks out so you can remove top yoke with steering lock on
Remove lock
Talk to Express keys Orpington Kent AKA:-
https://www.keysinthepost.com/

They will be able to strip the lock remove the key and cut an new one
Or cut you a key from the number and you get a new or second hand lock

There may be other good automotive locksmiths but I used express keys for over 30 years ! There not cheap but cheaper than the game of sorting all the locks on bike

Dave
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Dave
NC750Xdct + others at work !
davebike1@gmail.com

The Disapproving Brit · World Chat Champion Joined: 10 Sep 2008 Karma :

weasley · World Chat Champion Joined: 16 Oct 2010 Karma :

OP appears to be in USA, so I guess you'd have to look for a local option. I assume if you can get the barrel off of the bike then a locksmith would have a go at it. I recently had a key snapped in the lock of my topbox; I left it with a locksmith and for £15 he removed the stub and cut me a replacement. Not much use to you if you're in Cincinnati but anyone else looking I would recommend ESS in Swindon.
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