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Dismantling ignition barrel - pin removal

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Kwackman
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Dismantling ignition barrel - pin removal

#1 PostAuthor: Kwackman » Mon Aug 13, 2018 4:53 pm

Hi,
Trying to get into an ignition barrel, but these little pins are causing me trouble.
I've tried drilling them out, that failed!
So, before destroying another barrel, can anyone give me pointers on how to deal with these wee pins?
These switches are from an 81 Z400.
Cheers,
Davy
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2006 ZRX1200R
1982 Z400J project

ex owner of Z1100R
GXI 2752 are you out there?

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BykerBoy
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Re: Dismantling ignition barrel - pin removal

#2 PostAuthor: BykerBoy » Mon Aug 13, 2018 6:21 pm

That appears to be a roll pin and they usually are just driven in or out with a punch.
Why do you need it open?

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z1bman
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Re: Dismantling ignition barrel - pin removal

#3 PostAuthor: z1bman » Mon Aug 13, 2018 6:29 pm

use a self tapping screw & pull it out holding the screw in a vice

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MikeP
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Re: Dismantling ignition barrel - pin removal

#4 PostAuthor: MikeP » Mon Aug 13, 2018 6:31 pm

I agree with z1bman using a hardened self tapping screw or a small threading tap - although the latter is difficult to grasp to extract.

Good luck
Kwaki lover - Z1000R2, Z1000ST, ZXR750K1, ZX9R F1P, GPz1100B1 and a triage of H1As

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Kwackman
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Re: Dismantling ignition barrel - pin removal

#5 PostAuthor: Kwackman » Mon Aug 13, 2018 8:58 pm

BykerBoy wrote:Why do you need it open?

The original switch is jammed (key won't turn & steering lock is locked on), but anyway, there was a different key for the petrol cap etc. But my drilling skills etc today have knackered it beyond use anyway.
I bought a used key lock set (Ignition switch, petrol cap and helmet lock I think) of a ER500 which looked the same, all using the one key.
But the ER ignition barrel is actually about 10mm longer, and fouls the headlamp shell.
I was hoping to try swapping the actual barrel with the spring loaded levers across.
Over the last year I've gathered 2 other correct ignition switches, one with no key, one with a key but is a bit sticky! I'm still hoping to amend one of these with the ER500 innards...
What could possibly go wrong!

z1bman wrote:use a self tapping screw & pull it out holding the screw in a vice

That seems so obvious but it never crossed my mind! Thanks, I'll give that a go.
Thanks to MikeP too.
2006 ZRX1200R
1982 Z400J project

ex owner of Z1100R
GXI 2752 are you out there?

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pertonpc
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Re: Dismantling ignition barrel - pin removal

#6 PostAuthor: pertonpc » Mon Aug 13, 2018 9:28 pm

There are similar roll pins to hold Z1 fuel cap in place.

Soak with penetrating oil and then I selected a suitable diameter drill bit and tapped it out with that as a drift.

Obviously a vice or similar to hold it good and steady helps.

I also found the pins were more inclined to tap out from one side - so try both sides and see which moves first/ best then go for it.
Z1-R D1, Z650 B2, Z1-B & ZRX 1200 A1P Catch 'em if you can at www.Zedrider.co.uk

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BykerBoy
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Re: Dismantling ignition barrel - pin removal

#7 PostAuthor: BykerBoy » Tue Aug 14, 2018 4:42 pm

For future reference, when a steering lock key wont turn it's usually full of road crap. The best method I've found is to fill the barrel with Carb Cleaner or similar the push key in and out quickly several times then to put the key in the lock applying pressure as if to turn it and apply gentle heat until the liquid starts to boil, this gets it to flush out the road crap.
This pretty much always works for me.

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Kwackman
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Re: Dismantling ignition barrel - pin removal

#8 PostAuthor: Kwackman » Wed Aug 15, 2018 7:12 pm

Didn't have much joy using self tappers- I'll need to get smaller screws.
But, I think I got lucky.
Both barrels have a plastic cap at the bottom, the 400J is slimmer than the ER500 one, but they are interchangeable. This takes care of most of the height difference.
I'll go down this route as it's the easiest, and hope it fits OK.
Ta for the replies and ideas.
Cheers,
Davy
2006 ZRX1200R
1982 Z400J project

ex owner of Z1100R
GXI 2752 are you out there?


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