How to remove barrel from Buell ignition lock

[AEMan]

Hi all.
Customer bring Zadi Q903 ignition lock from Buell motocycle to make a key (all key lost). Lock have stamped 3 digit number on it, but key, cut to this number not working. Any one know how (in what position) I can remove lock cylinder from lock to directly read waffers and cut new key? Blade is ZD24FDP if it helps.

[p1et]

Post pictures of ignition lock.

[Weasel3]

If it has helmet lock. Maybe easier to remove. And work with this. To find a solution.

[AEMan]

Here is photos of the lock. Lock now in "engine off, steering unlock" position. I don't havewhole bike, only ignition lock.

[p1et]

I stripped exactly like this and it's very easy but unfortunately I don't have pictures so I will try to explain best I can:

- Measure blank ZD24 key from base to tip with caliper and then put into ignition lock.

- There is extra wafer at the end of barrell which need to be pressed down to release barrel. All you have to do is take distance from key base to tip and drill little hole just little further than that distance so you will reach the wafer which need to be pressed down and barrel will come out.

- I can't tell now from which side you need to drill hole but even if you do on wrong side it's not a big deal, just make exactly same hole other side of housing.

I hope it help. If you post more pictures, showing rest view of housing I can try to mark approx where the hole must be drilled for better understanding.

[AEMan]

Did barrel come out in any position of the lock or only in "ignition on" ?
There is one hole in the housing (you can see it on second picture) and I think it should give access to extra waffers when lock in ignition on position, but for some reason I can't pick it to turn in this position. Will barrel come out in ignition off position when waffer pressed?

[AEMan]

Here some more photos of this lock. As you can see I drill few holes where I think this waffer shold be, but no luck so far. If you can point approximate position of the hole it will be great.

[Fallen]

What is written on the ignition surround?
It should be QXXX

[AEMan]

It's Q933. If we talking about one on the side. Or it should be some other number on some plastic parts?

[Fallen]

Drill 4mm hole 32m from the FACE of the ignition.
Roughly in the spot marked.
Make sure its on the OFF position.

664994

[AEMan]

Thanks. It's late evening here. Will check tomorrow morning and report.

[p1et]

Yup this will be exactly / surely around this mark as Fallen described

[AEMan]

This feeling when you miss your target by just a millimeter..... 1.5 mm hole, drilled according to Fallen instructions and paper clip did the job from first try. :) Thanks to Fallen and p1et for great help. (all thanks buttons pressed :) )