If your lock is stuck this might be of help to you. I'm sure everyone knows how to get the steering stem head off, if not, look at this diagram:
www.illenium.de/gstwins/steering.png (http://www.illenium.de/gstwins/steering.png)
First off if your ignition is stuck in lock with the lock-pin engaged in the frame...you're in for some more trouble. Twist the key GENTLY until it can't go more, hold it with gentle pressure and tap the lock body with a wrench or other metal that will give it a good vibration. This may or may not work for you, but keep trying for 5-10 minutes. If it doesn't work, you have three options.
1) Follow the steps below while the lock is still on the bike
2) Break the lock pin, which I'm not going to detail, you cant get that part, you'll need a new lock if you want this function back
3) Cut off the steering stem head (cheaper on ebay than a lock set)
Now, this is with the steering stem head off the bike, you can do this on the bike but it will be a major MAJOR PITA, I suggest more wiggling and more tapping (gently!) while applying the proper motion to the key, have a friend help :cheers:
What do we need?
Small drill, medium drill and 1/4 inch drill
Philips screwdriver
Screw extractor
Needle-nose pliers
WD40
Grease (or other preferred lube)
Step 1) Drill a center using the smallest drill in the top TWO screws (the gold colored ones, don't touch the others just yet), these are fairly soft, make sure you are on CENTER. Now use the bigger one, widen the hole. Finally, use your screw extractor to get it out (counterclock wise). It didnt take much strength to get mine out. If you cant get them out, use the 1/4 inch to drill off the head (dont drill to far)
(http://www.illenium.de/gstwins/IMG-20130430-00798.jpg)
(http://www.illenium.de/gstwins/IMG-20130430-00799.jpg)
Step 2) now you can take the switch off, it doesn't matter if you take a look at the contacts and turn it, it only goes back on one way, the right way, you cant mess it up :icon_razz:
Use the pliers to gently pull out the white plastic part, lay it aside.
You are now looking at your lock pin and the mechanism that rotates the switch. You can only remove the
lockpin if you can move the key between the lock and off position (pretty self explanatory)
If your lock is stuck in 'lock' and you are luck enough to get it off the bike, this is the time to lube it with WD40 and again
turn the key while tapping on the body of the lock.
Step 3)
IM LUCKY >> Should your lock free up by now, blow it out with compressed air, replace everything, put in new screws (these are 4mm screws with a 0.7 pitch and 8mm long, you can get them at home depot/lowes/ace), done.
KINDA WORKS >> If its still hard to turn it but it comes around, proceed with step 4, if it doesnt move at all, tap while turning, it will come loose
if you have the RIGHT key, keep on spraying WD40 in it. I suggest you do the below and drill the two larger silver screws that hold the ignition in place out, its easier to proceed with the ignition lock off the bike from here on out
STILL DONT WORK FOR ME, WTH >> you need to replace the lock, if you cant get it free, this becomes pointless, to get it of the stem do this: using you smallest drill, make a starter hole in each of the two big silver bolts. Now use the middle drill, make it bigger and deeper, finally use the 1/4 drill, go in until the bolt head snaps (make sure you dont drill to far). I was able to get the rest of the bolt out with my fingers, you may need to use the visegrip.
These are 6mm screws with 1.0 pitch and 18mm long, lowes etc.., get a new lock, screws and reverse above.
Step 4) Remove the lock pin and bracket, set it aside
Step 5) Remove the two small screws BUT BE CAREFUL The gold plate is what limits turning the key, take it off, set it aside. Take the
part out that rotates the switch, there is a spring underneath and a tiny, TIIIIINY pin that may fall out in this or the next step, dont loose it. You'll see another little gold colored plate, the pin sits on the rim there. Look for the pin, better have if fall out now that you're paying attention, lay it aside
(http://www.illenium.de/gstwins/IMG-20130430-00818.jpg)
(http://www.illenium.de/gstwins/IMG-20130430-00819.jpg)
(http://www.illenium.de/gstwins/IMG-20130430-00820.jpg)
(http://www.illenium.de/gstwins/IMG-20130430-00821.jpg)
(http://www.illenium.de/gstwins/IMG-20130430-00825.jpg)
Step 6) now you got everything out you can get out without breaking something, spray more WD in the locking cylinder from below and through the keyhole, blow it out with compressed air, make sure this is CLEAN
Step 7) put some grease in there like in the last picture above
Step 8) to assemble in reverse direction, here are things to watch out for:
The last plate you took off fits in the part that rotates the electric switch, the silver part that rotates the switch fits on it in only one way. This will give you a better idea how it goes back together
(http://www.illenium.de/gstwins/001.jpg)
Step 9)
Turn the key in the ignition until it gets stuck in the off position (where you usually would push it down to get into the lock position), leave it in off for now.
The pin goes in first, than the smaller gold colored plate, next the spring, followed by the silver part that rotates the switch (which i will now call rotator), than the larger gold colored plate which is secured with the two small bolts. Note, the 'switch rotator' must move freely, if it doesn't, you didnt line up the 1st gold colored plate with the switch rotator correctly, this can be a pain.
with the key in the OFF position, you want it to look like this (notice the position of the ' rotator')
(http://www.illenium.de/gstwins/IMG-20130430-00836.jpg)
Check your lock functions properly, if not, that smaller golden colored plate is misaligned with the 'rotator'
If you did it right, put back the white plastic and line the switch up with the 'rotator' tip (you may need to turn the switch so it lines up), screws back in (remember, 4 mm 0.7 pitch 8mm long x2 for the lock and 6 mm 1.0 pitch 18mm long x 2 to secure the whole ignition on the steering stem) and it should work like new.
:cheers:
Now bash me for my bad English and over sized pictures :technical:
Good luck!!