Like many people (it would seem), I got my ignition out of alignment while working on the bike. My forks were locked and I could not get the forks unlocked no matter what I tried. I watched a lot of videos and resigned myself that I probably broke something in the ignition itself.

Before I special ordered a new ignition, I figured I would take it apart to see if I could align the tumblers myself. Here's what the guts look like in case you are googling and come upon this thread. Seeing what's inside may allow you to align the tumblers from above without taking it apart.

I did not take a photo of the actual lock part that is keyed to the tumblers. That is where the magic of your fork lock happens and how this stuff gets out of whack.

Basically three different parts of the ignition have the same tumbler pattern and they all must align AND they all must be in sync to the **** position on that black part you see where I ID'd the stops.

Hopefully, this will help someone. It's actually not that hard to take apart and put back together. THERE ARE SOME PARTS UNDER SPRING TENSION SO ALWAYS COVER IT WHILE YOU ARE DISASSEMBLING SO YOU DON'T LOSE ANYTHING.

 

For future reference... you could file off the outside tang of your key, then insert it into the misaligned hole. Presto change-o... back in business.

A locksmith can make a replacement if you want it with the tang... or have a copy made and file on it.

Ride Safely!
John.

 

This has nothing to do with the key. The rod attached to the ignition **** has to line up with three tumblers in the ignition cylinder. If those tumblers get out of sync, you are doomed.

 

Ahhh... thanks for the clarification.

Ride Safely!
John .