Help with ingnition install...

[JoeyG]

There's got to be a better way!

Long story short:  broke my only key, dealer said they could cut a new one if I brought the ignition in with proof of ownership.

I'm heading to the hardwar store to grab a centerpunch to tap out the Torx bolts.  This does not look like its going to be easy considering I have to do it while still on the bike.

Any suggestions?  Please HELP!

[themaffeo]

Heh. I just had the same problem.

1) Is the steering column locked?  If it is, you'll probably need to drill out the screws.  Don't ask me what that means... that's what the shop told me they had to do.

2) if the steering column isn't locked... those torx screws are SOB's.  i think they are a trox socket size 5 (pretty sure about that).  I couldn't find one locally so i had to order off the internet.

I had a wrench and couldn't get them to budge - it was suggested i use and impact driver but i never got around to it, ended up paying the $120 to have the shop do it for me.

Good luck....

[drooler]

Read this thread:

http://gstwins.com/forum/viewtopic.php?t=18750&highlight=key+lock+drill

Then, as is mentioned in that thread, learn how to use the SEARCH function, and you'll know how to help yourself in the future. If you don't SEARCH for help, you're going to miss out on a lot of good information. As you might have guessed, this problem has been dealt with by several other members previously. You can let THEIR experiences help you solve your problems, or you can do things the hard way, such as waiting for someone else to find your thread and type a reply.

Good luck; let us know how this turns out...

[JoeyG]

Thanks for the link.

Looks like even if I drill a pilot the center puch I got still won't fit in there.  I'll have to look for a small one tomorrow.  Any other suggetions welcome.  If I don't find a smaller center punch I'll have to give a locksmith a call.

Thanks.

[DerekNC]

I had to replace my ignition back in the winter because the previous owner busted everything out. It's actually not that hard to drill the bolts out. I found that if you drill directly from the front of the ignition straight through where the head of the bolt is works good. You only need to drill the head of the bolts off. Once they're drilled out you can then slide the ignition out and unplug it from the harness inside the headlight shell. What's remaining of the bolts can be removed with finger pressure.

[Soaring]

did you break it in the ignition? I just broke my key in the gas cap last week and fortunately managed to get it out with partial cap disassembly, took both pieces to the locksmith and now got two brand new keys for $10. see if you can get the broken piece out.. otherwise it looks like things can get pricey

[Budrick320]

So you don't have to get a key from the dealer??

I lost my second key the first two weeks I got the bike and I was wondering if these keys have like a chip in them. You know how newer cars can only be started with a 'real' key. If so I can save some money by going to a locksmith or Home Depot.

[Soaring]

I never heard of chipped keys, but my GS is 1990 and I doubt they had anything like that then anyway, I am a broke international student so after seeing that new ignition and gas cap would cost something like $400 together I just took the cap apart, got the key piece out, took both pieces to the locksmith along with the cap to test it right away and it worked beautifully, took less then 5 min. Then I went back to check whether it works in the ignition as well. Got a second one after making sure it works. $10 for two keys. A huge relief for somebody who figured it'd be another $400 before he can ride again

[JoeyG]

I didn't break the key off in the ingnition...I have both pieces.

I'm going to take them to see if I can still get a key made.  It so I pulled my bike apart for nothing but, at least I won't have to deal with those Torx bolts.