Yamaha pannier lock cylinder fell out

[herbivrus]

Argh!

Somewhere between work and home today the lock cylinder on the right hand pannier (the OEM sidecase) fell out of the case, so that I can neither open nor remove the thing. Frustrating, as I've rarely used the thing thus far -- I had the cases on this week for some errands -- and now it's permanently secured to the bike and useless at the same time!

It was installed by the dealer, as I bought the bags along with the bike when I purchased last spring. I'll obviously bring it in for them to make good (well, hope they'll make good; I've heard some less-than-promising things about the dealership's customer care lately), but wonder:

1. Is there some trick I can use to open the bag and/or remove it from the bike without the lock cylinderyi in the meantime?

2. Will the dealer be able to rekey a replacement cylinder to work with my bike key so I don't need to worry about carrying multiple keys to access my bags? One of the reasons I got the OEM bags was for that convenience, but if that's lost and the bags prove to be fragile in this way, I'll be pretty disappointed. Having one key for each bag would be annoying and problematic . . .

Love the bike otherwise, but the bags have seemed fussy from the beginning, and now one of 'em is just a useless tumor hanging off the thing's rear end. For that much money, I'd've liked to see a higher quality product. Maybe it's time for aftermarket bags, making the $1000+ spent on the OEM bags wasted dough. Sheesh!

 

[hANNAbONE]

...and thus why I purchased Jesse's...

sorry for your misfortune...

 

[rocca]

Same happened to me.

To remove case - assuming the metal housing into which the barrel slots is still there - use the lock barrel from the other case (unscrew it, slot it in the case to be unlocked, screw it up).

I couldn't get a key for the replacement barrel coded to the bike's ignition key. You can buy a set of barrels, I think, so that at least both cases will be on the same key.

Solution to the problem is to use thread lock on barrel screws.

 

[erenet]

I think there is a way to access the lock cylinder from inside, read here. http://www.yamahasupertenere.com/index.php?topic=5452.msg96171#msg96171

 

[EJV]

Been Here. Done that.

You can "re-key" the lock cyl for the bag to match the rest of the bike.
Dealer can't make the keys match from any ordering options.
--Serious, you can't get all the sets to match.

Follow these steps:
-Buy a new Lock Cyl (or 3) from your Dealer.
-Throw out the key that comes with the new Lock Cyl.
-Crack open a Sam Adams and take a swig.
-Re-arrange the 5(?) plates to match the existing key.
--They pull out with needle nose pliers and pop back in (and stay).
--Re-arrange as close as possible to be flush with the key in the Cyl.
--File as needed.
-Pop the inner cyl back into the body.
-Loctite the Sh1t out of the screws.

-Go ride and be happy.

EJ

 

[bloodline]

The installation instructions specifically call for loctite. I'd be a little pissed at my dealer...

 

[terrysig]

Bought the top box while i decided which sides i wanted. asked the dealer point blank...do you loctite. oh yeah...of course.

had the torx from the FJR days. no way did they loctite...and it was loose since they probably didn't have the torx.

that has to be part of any new owners day one checkout procedure if you also bought the boxes.

 

[HoebSTer]

YOU CAN GET INSIDE WITHOUT MESSING WITH THE LOCK OR BREAKING SOMETHING. While the bag is on the bike, you can remove the 8 screws from the bottom bag plate. Also remove the 4 screws which hold the bracket (on bag) to the foot-peg bracketry. The whole bottom can then be removed and give you access to move the locking mechanism to remove it from the bike.
Then contact dealer, and loctite the hell out of it!!!

 

[herbivrus]

Thanks, everyone:

Managed to get the bag off, and will get the set to the dealer and insist that they replace the lock cylinders on both bags with matching locks so at least I'll only need one key for both bags, even if they'll no longer match the ignition key. (Or try EJV's method for rekeying the tumblers to match the ignition key.)

It's disappointing, though not entirely surprising, that the dealer would have skipped the loctite step in assembly -- such a tiny savings in time can really mess things up for your customer in the future!

I'd been thinking of investing in a set of Jesse bags or Zega Pros, too, so maybe I'll just get these both set up with new cylinders and sell them to offset that cost. We'll see . . .

 

[roy]

Even after you loctite the little screw(s) many times over you will still find that they still work loose. A tack weld on them might cure the problem but loctite is not 100% the end of the story. I just check mine often and yes they are almost always loose even with a lot of loctite applied. I have not tried red loctite yet but I am almost to that point, the blue is not doing the job. Very irritating problem IMO.

 

[EJV]

If you're not into popping tiny lock pieces apart, a Locksmith would be able to "adjust" the cyl's to match too.
They come apart easy - Inner Barrel with tiny pieces and Outer Housing.
I lucked out with minimal filing.

I bought a set of three (to match the boxes) and a single one (to mess with). The single one worked. I have a spare set of three now.

Generous amounts of Red Loctite was put to use. ::013::

EJ

 

[MikeBear]

Thanks for the info. ::008::
It would really suck on a long trip in the middle of nowhere.

 

[tomatocity]

The installation instructions specifically call for loctite. I'd be a little pissed at my dealer...

::026::

 

[autoteach]

I installed mine and my dealer still warrantied the lock when it came out. I used a lock ring pliers to turn the metal plate that the lock attaches to. really easy, nothing to disassemble

 

[Leftlane]

The lock fell out of my top box as well. The dealer asked me to phone Yamaha Canada there reply was that accessories are only warranty for 90 days. They also said it was the first time they had heard of this problem. Bullsh!t. So Yamaha has to here from all of us. I directed them to the forum to hear our comments. My dealer SGpower ordered the lock to fit my ignition key and are going to repair it. They are going to do the right thing and keep a customer happy.

 

[Motowalt]

I bought my panniers used, and before I installed the lock cylinders, I inadvertantly closed one lid and locked it ::010::
(the tiny blocking screw which keeps the arm from locking had already been removed by the first owner...)

To open the lid, I used a wooden dowel wrapped with gaffer's tape and was able to turn the mechanism to release the lid.