From memory.... (I've done this a few times, but not for a while).
It's a LOT easier if you have the correct key (ie your key).
FIRST - order yourself a selection of lock wafers from somewhere (
Motorworks do a kit). WAIT FOR THEM TO ARRIVE.
Insert the key (this will unlock all the wafers from the barrel, apart from the bottom one, which is the wafer that locks the barrel into the cylinder).
Insert a probe into the small hole INSIDE the pannier casing which aligns with the end of the lock barrel, with the barrel rotated to a certain position (I can't remember what position this is - either fully locked, or fully open) - this will unlock the end wafer, and you "should" be able to pull the barrel (with the key in it) SLOWLY out. Be patient - this can take some fineagleing and swearing. The end wafer might try to make a bid for freedom as you pull the barrel out.... don't let it.
KEEP THE KEY IN THE BARREL.
On a clean worksurface rotate and observer the barrel, you'll see all the wafers are nicely pulled into the barrel. (apart from the end wafer which will be pushed out by it's spring.... assuming it's still there and hasn't pinged across the workshop....)
SLOWLY, and with your fingers covering the wafer ports, retract the key out of the barrel and you'll feel the wafers get pushed by their springs out of the ports.
Take the NEW key (ie, the NEW owner's key), and insert it into the barrel.
Observe that SOME of the wafers will NOT be fully retracted into the barrel.
One by one, remove the wafers that do not fully retract, and try a different wafer in that position. There are 3 different wafers, and they SHOULD be stamped with a number (1-3) to make it easy to figure out which one you've already tried.
BE SURE that ALL the wafers retract FULLY into the barrel. If there's even a fraction of a mm of the wafer exposed, the barrel will potentially jam in the cylinder and not rotate (and also be a bugger to get back out).
If I remember correctly, the end wafer doesn't get changed.
If I further remember correctly - the 2nd to last "wafer-port" on the panniers is left empty - this wafer IS used on the ignition barrel, but not on the panniers - it's the wafer that locks the key in the barrel when the barrel is turned to the "on" position (or "open" for the panniers).
Once you have all the wafers replaced, and retracting FULLY into the barrel, with the key IN, push in the end wafer and re-insert the barrel into the cylinder. Push it until there is a "click" noise - that's the end-wafer engaging.
CHECK FOR FULL FREEDOM OF MOVEMENT. As said, if the wafers do not retract FULLY in the barrel, then the barrel won't be free to rotate properly, and you'll be swearing again while you try to get the barrel back out of the cylinder.
I make no guarantee as to the accuracy or reliability of these instructions.
