Replacing Pannier Lock Assembly & Key Tumbler - Updated 7/4/13

[Highett]

I had a replacement right side pannier as part of the repairs to the GTR from my wildlife incident, the problem was when the pannier turned up it came without the lock assembly.

Seems that was a separate part number, go figure.

Anyway as I was going on a long trip I fitted the old lock assembly, it was a bit scratched but still worked....the rest of the old pannier was toast, glad I kept it though.

The new lock assembly came with a new a new key tumbler and two keys and was not keyed alike to my bikes keys.

What I wanted to do was remove the original key tumbler from the old lock assembly and use it in the new lock assembly so that both my panniers were keyed alike.

My first go using a video for something like this, would have been much better with someone on the video instead of a tripod, so a bit of a learning curve - Learning all the time, next one will be better

I had the video set up looking down on the desk but unfortunately there are bits that were out of camera, commentary was recorded so its not to bad and there are some photos in it too.

Click on the Picture to view the video:



Cheers

Paul

[O.C.]

10/10 for the repair, 6/10 for film direction 

Seriously, that's a job well done and now the matching key set is as it should be, its concerining to see how easy it would be to cut through the plastic lock bar on the cases, I'm not sure what could be done about that

Thanks for sharing the information   

[PCPeteUK]

Seriously, that's a job well done and now the matching key set is as it should be, its concerining to see how easy it would be to cut through the plastic lock bar on the cases, I'm not sure what could be done about that

Have a look at a number our Italian friends video's (MG). He shows how to 'protect' the cut through fairly simply by inserting Allen keys through the mounting points - simple, unobtrusive and very effective....
If I can find the link I will post it here. Well worth the little trouble to undertake initially for the added peace of mind.

[Highett]

Have a look at a number our Italian friends video's (MG). He shows how to 'protect' the cut through fairly simply by inserting Allen keys through the mounting points - simple, unobtrusive and very effective....
If I can find the link I will post it here. Well worth the little trouble to undertake initially for the added peace of mind.

Yes I have seen similar posts with photos of a locking pin inserted from inside the pannier on each hanger which prevents removal from the bike, to remove the pins requires unlocking and opening the pannier.


Since I have removed and replaced the lock tumbler and have had time to examine the spare tumbler carefully I now see another weakness which is even more scary.


I mentioned in my post that I thought that locksmiths would have a tool to reach into the tumbler key way and release the retaining clip at the bottom allowing the tumbler to be removed with out damage.


I now believe that is is very easy to do.


That being the case, I would not leave valuables in the panniers, locked or otherwise.


Cheers


Paul

[O.C.]

It is worrying that security isn't as good as it could be.

Maybe KHI coulod address the situation for the next model year GTR. The only problem is that the bike wouldn't look any different to the current model and that wouldn't sit well with the marketing dept;....or is that just me being cynical      

[hurricane]

All this goes without saying, no matter what the bike. I would never leave panniers on a bike overnight if it's not at home in my garage. For me, that leaves just the problem of the short side trips and longer lunch breaks as a risk. Almost never a problem riding Australia, except for in the cities. Not a problem either - as I avoid cities since they are simply a time vampire!.

[Highett]

Update  7/4/13

I had a closer look at the spare lock tumbler that I had  and realised that I could have saved myself a bit of frustration had I research locks a little more, removing these is even easier than I first thought.

A removal tool made from a used hacksaw blade, 1st tool was too narrow at the tip, it worked but took a lot of fiddling, because it was too narrow it slipped off the locking clip.

The second tool worked as quick as the key, and because with the tumbler removed a flat blade screw drive would be needed to reach in to unlock the pannier I made the tool double ended, one end to remove the tumbler the other end to unlock the pannier.

Here's a photo the tools and lock tumbler.



Click on the Picture to view the video:



Cheers

Paul

[O.C.]

That was made to look very easy ...I hope local scrotes don't get the same ideas, as I assume the same principal applies to all barrel locks on bikes, 

[Highett]

For other bikes I don't know, different makes of panni r or top boxes may be different.
Fuel cap seems to be different, I did give it a try just to see so that was pleasing.
Given what the cost of the Pannier, you would have though it would be secure :(

Cheers

Paul

[O.C.]

For other bikes I don't know, different makes of panni r or top boxes may be different.
Fuel cap seems to be different, I did give it a try just to see so that was pleasing.
Given what the cost of the Pannier, you would have though it would be secure :(

Cheers

Paul

[Boomer]

The lock is intended to make sure that the pannier does not fly open when riding.
It provides basic security but please do not assume that it is secure.
If a tea-leaf sees your iPad in yer panniers while you are getting something out of there he will be back 5 mins later with a screwdriver and your iPad is gone, and you may also need a new pannier. My old GTR1000 panniers were more secure than these.

[shaggs147]

Thanks for the heads up Paul.
The only time my panniers are at risk really is when i'm stopping off for a break and a coffee somewhere. I always remove the panniers and leave them in the hotel / house at the end of a ride. I know a plastic box is no real challenge to a thief, but I would've thought the lock would be a little more secure than that. It still amazes me how much companies charge for panniers, they must cost a tenner to make.