Ignition barrel extraction | GTAMotorcycle.com

Ignition barrel extraction

PaisaMed

Well-known member
My ktm990 had a screw jammed into the ignition barrel by a would be thief. I have carefully removed the screw and, of course, my key wont go all the way in probably because some of the tumblers are euchered. I need to get the barrel out of the bike. Anyone talked this? Remove the triple tree and drill out the security screws? Thanks for any tips.
 

TK4

Well-known member
My ktm990 had a screw jammed into the ignition barrel by a would be thief. I have carefully removed the screw and, of course, my key wont go all the way in probably because some of the tumblers are euchered. I need to get the barrel out of the bike. Anyone talked this? Remove the triple tree and drill out the security screws? Thanks for any tips.
It looks like (from the parts list) that the switch is held on to the upper triple clamp by two 4X12 flathead screws. Maybe no drilling required ?
Replacement switch part # 60011066000
KTM.SparePartsFinderFrontend
 

Trials

Well-known member
The normal setup, was to locate ordinary screws to hold the lock in a place that was hard to access, when the steering was full turned and locked. Never seen one on there with special anything screws. ymmv.
... is a total crap setup anyway, the separate steering locks are marginally better if only because they have 2 things to deal with.

Is a shame the thing did not blow up and burn the thieving !@#$%s hand.
 

Mad Mike

Well-known member
Should be 2 cheese-head Phillips screws that gets unscrewed from below. I've never seen a bike that asks for the triple to be removed, you might want a long flex shaft and a small impact gun. I doubt you can repair the assembly.
 

PaisaMed

Well-known member
Update: I would prefer not to remove the top triple but so far I popped out the headlight/instrument cluster and still can't see these ignition barrel bolts. So, off comes the triple and because the steering is locked, I can't access the left fork bolts so the off comes the tank and I can't get the right side tank bolt off because it's covered by a piece of bodywork which I can get off because the previous owner had a GoPro mount mounted with adhesive that covered the front right side bodywork bolt. And, did I mention that the bike is at least a hundred feet from the nearest power outlet. I now need a hairdryer and a long extension cord and a stiff drink! Fack, I need a garage badly!
 

PaisaMed

Well-known member
I'd like to get the barrel out and remove all the internals and then reassemble it. No one will know that a key is not needed to turn the ignition on. And that way I can keep the same key for the gas cap and the seat release. Will this idea work?
 

PaisaMed

Well-known member
Hey everyone, I'm still working on this matter. Regarding the gas tank and it's removal, there are hex heads, Torx heads and 2 big Phillips heads. Couldn't be consistent now, could you Ferdinand Von Austria! Anyway, I will continue another night. On a happier note, I did manage to remove the GoPro mount using an exact knife. Who puts a mount over a bolt hole?
 

GVH

Well-known member
Is this what it looks like. I usually use the edge of a flat screw driver and a hammer on cars. Bikes seem to have locktite most of the time.

 
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PaisaMed

Well-known member
Thanks for those pics! That's my plan...either drill out the screws or make them flat head screwsriver removable. Because my steering is locked, I'm concerned how the steering lock bolt will be liberated. I'll know more tonight when I get the triple off.
 

GVH

Well-known member
That is the bottom of the ignition. You could turn it with a screwdriver to start the bike. Doeseffect the tumblers or steeringlock

you may have to remove forks to slide the steeringlock out. If your lucky it might be a bolt on bracket like the Grom was.

maybe try to wiggle the key in. To unlock
 

PaisaMed

Well-known member
I have the ignition barrel and related switch out of the bike but not before I had to use those lovely tools called the hammer, hacksaw, and chisel! It turned out that on my bike (ktm990), I did not have to remove the top triple tree. Once I got the headlight and instrument cluster removed, I could see the two
security bolts and their heads were sheared off which I think is a part of the install process. I thought I would create a flathead screwdriver groove and the simply turn them out but they were well recessed into the surrounding aluminum. What ended up happening was an all out assault on the soft aluminum with the hammer and chisel. I mined enough aluminum surrounding both bolts to be able to grab the heads with vice grips and slowly twist them out 45 degrees at a time. Now I have the Zadi ignition and I need to get the actual barrel out of the housing and repair or replace all the tumblers.

This was a royal pain in the ass!! However, the steering lock did its job and I have still have my unicorn! I'm thankful this didn't happen during riding season.


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PaisaMed

Well-known member
Anybody have any brilliant ideas on how to extract the tumbler barrel from the housing? Is there a pin that needs to be pushed in for release?
 

GreyGhost

Well-known member
Site Supporter
Anybody have any brilliant ideas on how to extract the tumbler barrel from the housing? Is there a pin that needs to be pushed in for release?
Let the new cylinder be your guide. You might be able to see a screw hole or tab that is not associated with the lock pins.
 

PaisaMed

Well-known member
The reason I had to go all caveman on this bike was that with the steering locked the top triple can not move in an vertical direction. Also, it cannot move in an outward direction (toward the front tip of the front fender). There is only one option and that is to remove the two security bolts holding the ignition assembly. Now I probably could have been a little gentler but my patience has long gone as this attempted theft happened 2 months ago. Thankfully, I'm not a dentist!
 

PaisaMed

Well-known member
progress:

I now have a key stuck in a Jim Bob welded ignition cylinder because I forgot about pulling it out while the material was setting! lol, I am not a sculptor!

I'm rolling around a few options on how to finish this pain in the ass project cause I'm definitely not riding with this set up.


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