Ignition replacement or removal of a key... - Suzuki GSX-R Motorcycle Forums Gixxer.com
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post #1 of 23 (permalink) Old 07-24-2009, 10:59 PM Thread Starter
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Ignition replacement or removal of a key...

1992 Gixxer 600:

When I took my key out after my ride to work the other morning, only about 25% of the key came out. The rest is still in the bike. I was able to start it with the stub of the key that I had a few times, but that stopped working.

I am assuming that I will need to get a whole new ignition and a gas cap lock because the portion of the key does not want to come out. I tried needle nose pliers and super glue on a small allen wrench. The part stuck inside just does not want to budge. I'll call the dealership tomorrow and talk to someone there.

So I guess I have a couple questions;

Other than welding a piece of metal to the end of the key, does anyone else have any suggestions?

Does anyone have a gas cap and ignition with the same key for sale?

Thanks.

-jm
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post #2 of 23 (permalink) Old 07-24-2009, 11:02 PM Thread Starter
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Re: Ignition replacement or removal of a key...

Or; if I take apart the ignition, would it be easy to get the portion of the key out? I can then just take the title to the dealer and have a new key cut. Sadly the guy I bought the bike from only gave me a single key.
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post #3 of 23 (permalink) Old 07-24-2009, 11:33 PM
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Re: Ignition replacement or removal of a key...

do a race ignition. cut the wires and put a switch somewhere... other than that you gotta buy a new ignition and gas cap
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post #4 of 23 (permalink) Old 07-25-2009, 12:01 AM Thread Starter
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Re: Ignition replacement or removal of a key...

Is there a write up for that?
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post #5 of 23 (permalink) Old 07-25-2009, 07:54 AM
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Re: Ignition replacement or removal of a key...

Quote:
Originally Posted by Jakemetz63 View Post
Is there a write up for that?
A write up? You have the four wire ignition that doesn't have the resistor in the housing. You need to connect the RED wire to two of the other wires. The extra wire is to light up the rear tail light when you put the key in the "park" mode. Do you have a wiring diagram for the bike?
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post #6 of 23 (permalink) Old 07-25-2009, 11:08 AM Thread Starter
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Re: Ignition replacement or removal of a key...

No I do not.
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post #7 of 23 (permalink) Old 07-25-2009, 11:37 AM
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Re: Ignition replacement or removal of a key...

I had that happen. Take a coping saw blade, cut it off and slide it in past the key with the teeth angle back towards you. You can usually hook the key and and pull it out.
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post #8 of 23 (permalink) Old 07-25-2009, 12:18 PM Thread Starter
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Re: Ignition replacement or removal of a key...

There is the red wire, a thick grey wire and a thick orange wire. There is also a very thin brown wire. I am assuming that the brown wire is for the tail lights due to it being so much smaller than the other 3.

Looks like I will go ghetto style and wire up a race switch today.
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post #9 of 23 (permalink) Old 07-25-2009, 05:16 PM
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Re: Ignition replacement or removal of a key...

I think you are correct with the brown wire for the "park" function to light the rear lamp and the little lamp above the headlight. Wire the large Red to switch power to the grey and orange and you are set. At least till you get a new ignition barrel.
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post #10 of 23 (permalink) Old 07-25-2009, 05:22 PM Thread Starter
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Re: Ignition replacement or removal of a key...

After talking to the suzuki mechanic and another lock smith, I decided that "Hey, I can't really fuck it up any worse" and made it so that anyone with a screw driver can start my bike. Time to get a lock.

Anywho, need to buy a key less gas cap and swap it out.

Edit*

How the hell do I get the locking gas cap off and replace it with a new one? I removed the silver ring around it, no problem. Does the gas cap screw on or is it snap down?

Last edited by Jakemetz63; 07-25-2009 at 05:42 PM.
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post #11 of 23 (permalink) Old 07-25-2009, 05:50 PM
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Re: Ignition replacement or removal of a key...

mine screws in with allen screws
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post #12 of 23 (permalink) Old 07-25-2009, 06:01 PM
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Re: Ignition replacement or removal of a key...

If the gas cap is locked in (it's a snap down), you'll have to drill the lock out to release the catches - I've done it but it's a two person job: one to hold the tank steady and the other to do the drill magic.

Start with a small pilot hole in the center of the lock (1/4 inch or so) and then go increasing larger. I ended up at 7/16ths before it released. You might get lucky and have it release sooner though.

Be patient!
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post #13 of 23 (permalink) Old 07-25-2009, 06:35 PM Thread Starter
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Re: Ignition replacement or removal of a key...

I am truly a master of ghetto engineering. I undid the allen wrench screws for the silver ring and then snapped the attachments to the locking gas cap. I pried off the gas cap (that was kind of tough) and undid the screws on the bottom to remove the locking mechanism and reassembled it.

Now, the cap doesn't attach to the silver ring anymore but this will work until my replacement comes in. I now own a fully key less motorcycle, though it appears completely stock unless you really look at it.

Time to go buy one of those steel wheel locks.
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post #14 of 23 (permalink) Old 07-25-2009, 09:37 PM
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Re: Ignition replacement or removal of a key...

Just be glad it wasn't a 94+ ignition. Those suckers have extra wires that you have to solder in a resistor so the computer powers on.
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post #15 of 23 (permalink) Old 07-25-2009, 09:46 PM Thread Starter
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Re: Ignition replacement or removal of a key...

Before:


After:




I need to finish getting the glue off tomorrow. I like the way it looks much better without the fairings and decals.
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post #16 of 23 (permalink) Old 07-26-2009, 03:45 AM
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Re: Ignition replacement or removal of a key...

If you plan to wire up a key swith shoot me a PM and I will send you a picture of mine wired up. mines a 92 OC 750 but the ignition wiring is the same from what I read in this thread.
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post #17 of 23 (permalink) Old 07-26-2009, 04:33 AM
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Re: Ignition replacement or removal of a key...

you pretty much crimp all power wires together and run a toggle in line with the hot coming from the battery. that or just run a battery disconnect and leave the ignition on all the time
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post #18 of 23 (permalink) Old 07-26-2009, 07:53 AM
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Re: Ignition replacement or removal of a key...

Hey man, where do you park your bike? I need some parts!!

Just kidding around.. Get a new ignition switch. They sell Emgo replacements on eBay for $25-$50
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post #19 of 23 (permalink) Old 07-26-2009, 08:10 AM
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post #20 of 23 (permalink) Old 07-26-2009, 09:13 AM
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Re: Ignition replacement or removal of a key...

I thought he might've at least tried the broken coping saw blade first.
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