Saddle bag lock tumbler install instructions / video?
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Anything you have would help, thanks!
Eugene, I looked and I'm sorry but I don't have them anymore. I saved the extra tumblers for some reason but not the instructions or else the instructions were lost when I had a pipe burst recently.
However, I remember how I got it. I bought an official Kaw repair manual and it wasn't in there. So I went back to the dealer and asked where I could find the instructions. He got on his system and printed them out for me. My suggestion would be to ask the dealer that you bought the bags from for help. I believe that it's probably located in a repair manual supplement. Frankly my dealer was sympathetic that I wanted to do it myself.
It's a fairly easy process. You put all of one type of tumbler in (they are color coded) and then you stick the key in. I THINK the way it works is that the ones that are flush are correct. So then you try the next color coded set for the ones that are not flush. However, I'm not 100% sure and if you key it wrong and then install it in the bag, you are royally screwed. there is also some kind of trick to putting the lock in the bag. So get the instructions. If you get them, you won't have any trouble. So don't give up on doing it yourself.
I hope this helps.
However, I remember how I got it. I bought an official Kaw repair manual and it wasn't in there. So I went back to the dealer and asked where I could find the instructions. He got on his system and printed them out for me. My suggestion would be to ask the dealer that you bought the bags from for help. I believe that it's probably located in a repair manual supplement. Frankly my dealer was sympathetic that I wanted to do it myself.
It's a fairly easy process. You put all of one type of tumbler in (they are color coded) and then you stick the key in. I THINK the way it works is that the ones that are flush are correct. So then you try the next color coded set for the ones that are not flush. However, I'm not 100% sure and if you key it wrong and then install it in the bag, you are royally screwed. there is also some kind of trick to putting the lock in the bag. So get the instructions. If you get them, you won't have any trouble. So don't give up on doing it yourself.
I hope this helps.
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350 Posts
That helps a little bit... any other useful tips would be appreciated. Heh.
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350 Posts
Woohoo! I did it! Your advice was just enough to get me through it. It wasn't that bad at all, actually. Now I feel like a pro locksmith
The rubber things go on the passenger foot peg brackets and the cases slide into them to locate.
Under the tool kit you will see 4 bolts the thread into the rear fender. Undo them and two bolts just in back of the battery on the left and right side of the plastic under tray. The under tray should be loose but its over two tabs at the front. You have to spread it out slightly to lower it.
After you lower the under tray you will see a cut out on each side to follow that you have to cut out to mount the rails. Cut those out. Put the back bolts in where the cut outs are first, then the front bolts. Oddly they have to be done in this order. Also it's easy to get the front bolts cross threaded because everything is a tight fit. So make sure you hand start them.
BEFORE YOU DO ALL THIS PUT SOME TAPE OVER THE MOUNT FOR THE SHOCK ADJUSTER AND THE UNDER TRAY TO KEEP THE ADJUSTER FROM SCRATCHING THE UNDER TRAY. The ECU is bolted to the under tray. You can detach it or just be sure you don't strain the wiring to it. I had enough slack that I didn't detach it.
Under the tool kit you will see 4 bolts the thread into the rear fender. Undo them and two bolts just in back of the battery on the left and right side of the plastic under tray. The under tray should be loose but its over two tabs at the front. You have to spread it out slightly to lower it.
After you lower the under tray you will see a cut out on each side to follow that you have to cut out to mount the rails. Cut those out. Put the back bolts in where the cut outs are first, then the front bolts. Oddly they have to be done in this order. Also it's easy to get the front bolts cross threaded because everything is a tight fit. So make sure you hand start them.
BEFORE YOU DO ALL THIS PUT SOME TAPE OVER THE MOUNT FOR THE SHOCK ADJUSTER AND THE UNDER TRAY TO KEEP THE ADJUSTER FROM SCRATCHING THE UNDER TRAY. The ECU is bolted to the under tray. You can detach it or just be sure you don't strain the wiring to it. I had enough slack that I didn't detach it.
Calandris, I would PM Eugene and get him to describe the procedure for putting the lock in the bag after you get it keyed, while it's fresh in his mind. I remember the instructions as being a bit finicky about how you did it but don't remember the details.
Draw a picture of both lock cylinders on a sheet of paper. Indicate which is the key end. Draw the wafer slots and number them 1 thru 5. Do not install the springs yet. Keep the wafers separated by color code. Install a wafer in slot 1 (push in with small screwdriver using flat side). Install key in cyl and put pressure on wafer. It is the correct size if it rests perfectly flush w cyl. Record color for slot 1 on paper. Repeat for remaining slots. Remove wafer one at a time and install spring, reinstall wafer. Repeat for remaining slots. Then do 2nd cyl using colors recorded from 1st cyl. Ensure all wafers are flush w cyl w key installed, insert in bag while rotating clockwise and pushing lightly till cyl bottoms then push into place. You will hear a click. All this may sound difficult, it's actually quite easy.
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you can do this multiple ways, I put all of one color in first, then swapped out the ones that weren't correct to all of the next color, then swapped out all of the ones that weren't correct to the next color...and so on. Pictures below. took me 30 minutes, If i had to do it again it would be 5 minutes.
Key and tumbler contents
![Blue Art]()
Put springs in tumbler
![Technology Electronic device Electronic component Capacitor Electronics]()
Stick key in (Key is a little tough the first time as it sets the wafers)
You can see that 1 and 4 are correct, while 2,3,5 were wrong.
![Auto part]()
here is the way it looks when its all correct.
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![Technology Electronic device]()
Key and tumbler contents
Put springs in tumbler
Stick key in (Key is a little tough the first time as it sets the wafers)
You can see that 1 and 4 are correct, while 2,3,5 were wrong.
here is the way it looks when its all correct.
top
bottom
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