Join Date: Sep 2006
Location: Osprey, FL, USA
How to re-do lock cylinders
Do NOT drill anything. That is both foolish, expensive and wrong.
Take your case apart. It is very easy and allows acces to all the parts around the lock.
You do not need any special tools. Any slim pin will do. Just find the hole and push it in and the cylinder will come right out.
You need to get a "cylinder pins and springs kit" from your dealer. I got one from Haps in Sarasota Florida. Then take the cyclinder (carefuly) apart ... it justs pulls open, and you will find the "pins and springs" (I do not remember if there were either 6 or 8 of them).
You now need to figure out, based on your new key, which pins are number 1, number 2, or number 3. The kit and your existing lock both have the pins, and they are all numbered.
The pins are different lenghts (!!!) - Short, medium and long (the difference is quite small). Looking at your key, align the cylinder so that the pins correspond to the grooves in the key. Obviously the longer pin goes where there is a deeper groove, etc.
Put it all back together, and VOILA, it works. No need for a new cylinder, no drilling, no hastle. Just brains, perseverance, and the understanding that even BMW German engineers are not Gods. They designed a system that any technician around the world would be able to handle, assuming they know what they are doing. Unfortunately many do not, and furthermore, instead of being helpful they give us wrong information most of the time.
I re-did my R1200RT 2005 top case on my new K1200GT 2007 and it works perfect.
If you come to Sarasota Florida I will do it for you --- free !!!