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Old 09-23-2014, 01:11 PM   #1
AliveDK OP
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Question 950 - my ignition lock Mystery - Input needed

My ignition lock on my 2003 Adv. have been acting strange lately and a few time I have had trouble getting the key all the way in the lock and turning the key and start the engine. So rater that end up stuck somewhere I decided to buy a new original ignition lock with new keys (part number 60011066000) at 108 Euro….

Once received I have noticed that it comes with some strange mounting bolts. They are narrow in one end and while I have not yet removed the old lock they seem of a different design that the ‘original’ bolts:







- Does anybody know the reason for this bolt design, I really can’t see the reason nor advantage ?

- Also any hints to the easiest way to install the new lock ?
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Old 09-23-2014, 01:27 PM   #2
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when the bolt are torqued properly the hex head part will break off , leaving just a rounded head that can not be removed with a wrench. They must be drilled out,. it is a anti theft device,
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Old 09-23-2014, 05:46 PM   #3
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You will also have to use a drill to remove to original bolts, so you will need to remove the top triple clamp.
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Old 09-23-2014, 06:34 PM   #4
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I actually deal with those all the time. If you take a sharp punch and hammer you can get them off easy with out drilling. Just make sure you set your punch at angle before you start tapping the bolt out. Once it starts moving you can unscrew it with the awl if their isn't a ton of lock tight on it.
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Old 09-24-2014, 03:43 AM   #5
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Thumb So obvious once you know.........

Thanks a lot guys, makes a lot of sense, actually I’m a bit embarrassed I did not see it………..

Ok, so changing the lock might be more complicated that I imagined at first – most things are actually

Bajamcguide:
If needed is it not possible to drill out the bolt from below, avoiding removing the top triple clamp ?

Onewoodsrider:
Need to understand this correctly. I should use a punch and hammer to move (as in unscrew) the bolt. Once loose to continue with an awl and hand – Correct ?
Can this be done 'from below', or does it need to be 'from above' = having to remove the top triple clamp ?
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Old 09-24-2014, 04:02 AM   #6
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Will probably be hard to do with triple clamp in place.

Then the easiest would probably be to see if you can get a dremel in there and cut a slot in each bolt and back them out with a screwdriver.

Worked good on the 950 but on the 990 one of the bolts was so stuck I ended up drilling and getting stump out with wise grips once ignition lock was removed.

Impact screwdriver might to the trick if you are able to cut a good slot.

/Johan
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Old 09-24-2014, 09:50 AM   #7
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Not sure if there is enough room under the top clamp to position a drill to get at the bolts ? I changed one on my Superduke and I just removed the top clamp to make things easier. I just drilled enough to cut the head of the bolts, removed the ignition lock, than used a vice grip to unscrew the studs.
HTH Tim
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Old 09-25-2014, 09:30 AM   #8
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Tks your input. Will give a try ASAP
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Old 09-25-2014, 09:39 AM   #9
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I've used the method DirtyADV suggested to remove the bolts.
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Old 09-25-2014, 10:33 AM   #10
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Quote:
Originally Posted by Hipster View Post
I've used the method DirtyADV suggested to remove the bolts.
With or without removing the top trippel ?
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Old 09-25-2014, 01:20 PM   #11
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Originally Posted by AliveDK View Post
With or without removing the top trippel ?
I have always removed them, first to install Scotts upper triple for steering damper, they supplied a spacer so lower can easily be temporary bolted in place without and upper in place.

Just a short piece of tubing but dont have dimension, a luggage strap around lower and up over frame to hold lower in place will also work ...had forks removed when doing it so just a small bungie cord was enough to hold the lower in place.

/Johan
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