Yamaha Pannier Lock Stuck

Bill Simpson

Wheelstand Willy
Joined
Feb 18, 2016
Messages
6
Location
Cincinnati, OH
The lock on my right side pannier box is stuck. I can rotate key about 30 degrees in either direction but I hear no "click" at the center detente position. I regularly remove the boxes when parking the bike & have done so without issue many times. Installed fine in the AM, but lock was stuck after return from ride in the PM. So I can neither open the box nor can I remove the box from the bike. I know there have been lots of complaints about the funky locks on these Yamaha Accessory boxes. Anybody have a clue what I can do about this problem? I plan to call dealer to find out if any repair would be :question:covered under my YES extended warranty.
 

Bill Simpson

Wheelstand Willy
Joined
Feb 18, 2016
Messages
6
Location
Cincinnati, OH
After local dealer (not the one I purchased it from) told me that accessories are not covered by warranty, I attacked the problem myself. After inspecting companion box, I found the screws hold the lock into the latch mechanism had partially backed out. Theorized that perhaps one or both came out on the problem box. The rear hinge pins are pressed in from the outboard side of box, & inboard ends of the hinge are capped. I used a small brad nail & channel lock pliers to force the brad through the cap (very easy...pretty soft plastic) & onto the hinge pin, and then pushed the hinge pins out. Only outboard end of pin is knurled, the rest is smooth, so I only had to push it about 1/2 inch. Once both pins removed I could lift the lid from the hinge end, reached to lock end, removed rubber lock cap & confirmed that one screw was loose & the other was missing. I borrowed a screw from the companion box, installed it in problem box lock, tightened both screws, and was then able to open latch with key. I found the missing screw in the problem box. I re-installed the hinge pins, & used medium locktite on both screws of both locks & tightened everything up. Now everything is OK, & only evidence is small holes in hinge cap where the brad pushed through. I will check the tightness regularly now, since its fairly easy to do. Obviously, I was also then able to remove the box from the bike. Perhaps I'll post a tutorial with pics on the whole process, in case someone else has similar problem. ::008::
 

Gigitt

Active Member
Joined
May 15, 2015
Messages
427
Location
Sydney Australia
You can also undo the large screws from under the panier base, the base can be lowered enough get your arm up inside the pannier.
Undo the lock screws, pull the barrel out, use needle nose pliers to turn the plate to unlock the lid.

In a jam you can at least pull some gear out as all you need is a phillips head screwdriver.

Also another tip... carry gaffer tape, tape over the locks. if the screws loosen, the lock barrel will not fall out and be lost.
It also helps keeping dust out of the locks.

as said before tighten screws with blue loctite.
 

twflybum

Prodigal Biker
Joined
Dec 31, 2011
Messages
33
Location
Colorado
Something I just discovered this past weekend..

Was riding parts of the COBDR and part way through the trip my top box lock mechanism got really hard to open. It was so bad that I didn't want to close the lid completely (not locked) as I was afraid I would not be able to unlock it again. I just used a bungy to hold it closed for the ride out of the woods. Stopped in Telluride for fuel and found this product at the local hardware store and thought I'd give it a try..

http://www.bellautomotive.com/Bell-Automotive-Lock-De-Icer-p/22-5-00500-v.htm

The key/lock has never worked so smoothly! (Had the top box since early 2012) Very nice tip for getting the lubricant into the lock too.
 
Top