Ignition lock removal.

[DerekNC]

The bike I just bought had the ignition broke out because the previous owner damaged his key. Don't worry, I matched the vin numbers. But today I started to tackle the replacement. After I got everything loose to look up into where it attaches to the brace(or tripleclamp?) I couldn't tell what kind of bolts were holding it. At first I thought the bolts were broke off. But it now appears to be  like a very small star head bolt in it, and I mean very small. Are my observations correct and is this going to be another big headache?  :dunno:

Thanks a bunch.

Derek

[Jared]

It's an anti-theft type of bolt used in there -- like a t-15  (I think it's a 15...) torx with a pin sticking up in the center of the "hole"... I can't recall if it's a break away/one way bolt or not....(the torx part will break off if you try to take them off sometimes...  can't recall what's on the Gs at this second...).  

You can carefully drill out that pin an use the torx/star bit to try and take them out....or Just drill the whole head of the old bolts out and remove the ignition cylinder that way... once it's off you can take the remainder of the bolts out with your fingers usually.

Then just get  replacement bolts  from the hardware store.... (  allen key drive ones or something  like that..)

[cernunos]

You can buy the anti-tamper torx bits at Sears or your local tool supply outfit. They have a hole in the middle just for that purpose. Love the Baby G and this forum.

C.......

[DerekNC]

This forum has an amazing amount of knowledge. I'll either drill the head off or look for the special torx bit. Drilling may be easier as I suspect the head will break like  Jared said. Anyone know about what size the bolts are? Thanks for the help.

Derek

[The Buddha]

They are M6 X 1.0 I think ... same as the case bolts ... Just use allen heads ... Theft proof is over blown ...
Cool.
Srinath.

[mastrind]

the ones on my SV were T-40 torx bits (tamper proof).....I bought a kit at sears for $20.....here's the link...CLICKY!!!.....it's  a nice little kit to have.....

[dgyver]

The bolts that I have seen on the GS look like a male version of the torx. Not the safety torx that everyone is referring to but they may have changed them.

I could not get them off of a Katana clamp until I used a portaband and cut the whole dang lock off.

If you need another clamp and switch, I have one with a key.

[The Buddha]

The ideal too to remove those wiht minimal damage to the triple ... A used ... and worn and hence smaller diamater dremel tool cutting disk. I use then and when they wear and get small I save them. I have some that are positively tiny ... will get in there without hitting the sides ... and guess what ... if you're not cutting everything else around it cuts faster ...
Cool.
Srinath.

[mastrind]

The ideal too to remove those wiht minimal damage to the triple ... A used ... and worn and hence smaller diamater dremel tool cutting disk. I use then and when they wear and get small I save them. I have some that are positively tiny ... will get in there without hitting the sides ... and guess what ... if you're not cutting everything else around it cuts faster ...
Cool.
Srinath.

....dude....srinath.....no more drinking-then-typing binging.....seriously....I can't make out half of what you said....

[Jared]

Srinath is referring to cutting the lock cylinder off the triple clamp....

You can sorta get a hacksaw blade in there too if...but you usually end up cutting a little bit of the clamp (not enough to worry about  usually..it just follows the " line" between the plates......


Porta Bands are nice......I use one almost daily... Nice Milwaukee
Hey Harbor Freight  has a cheapie for 60$ right now .  We have one of those too - works great - no reliability issues at all..... The overall quality/feel is cheaper but a Milwaukee costs 300$.......

So the $60 one would be a great Joe-Homeowner version to own....

Great now I'm in a tool buying mood....

[DerekNC]

Come to think of it, the fastener does look like a male torx bolt. The head looked so tiny though I don't see how it would break loose without stripping or breaking. I may get some small torx sockets but in the end it will probably have to be drilled. I'll work on it today. If it turns out I need the clamp and switch I'll let you know dgyver. Thanks.

Derek

[cernunos]

If it looks like a male torx then it is an inverted torx bolt. You can usually find a plain 6-point socket that works just as well as the inverted torx bit in that case. Also helps if you rap the socket on the bolt a few times with a small brass hammer before loosening. Love the GS500 and this forum.

C.......

[DerekNC]

Well she's all taken care of. I ended up drilling the bolts out. It looked like the heads were already stripped so there was no sense in trying to unscrew them.
To remove them I drilled directly from the front through the old lock instead of up through the bottom. I started with a really small drill bit then progressed up to a 1/4" bit. After the head was gone they came loose with finger pressure just like Jared mentioned. New one went in with 6.0 x 20mm allen head screws obtained from Lowe's.
Sure beats using a screwdriver for a key.
   :lol:

Derek

[Sir Smapty]

Well she's all taken care of. I ended up drilling the bolts out. It looked like the heads were already stripped so there was no sense in trying to unscrew them.
To remove them I drilled directly from the front through the old lock instead of up through the bottom. I started with a really small drill bit then progressed up to a 1/4" bit. After the head was gone they came loose with finger pressure just like Jared mentioned. New one went in with 6.0 x 20mm allen head screws obtained from Lowe's.
Sure beats using a screwdriver for a key.
   :lol:

Derek

What size screw driver were you using?  I don't want to have to drill out this lock on mine. :mrgreen:

[DerekNC]

Medium sized Vermont American works best. :lol: