I am selling my panniers at the moment, and was putting together a quick how-to for the person buying them, so decided do stick it up here as it may be useful to others.
This is not a difficult task, but it is very fiddly.
Removing lock barrel from Pannier
Step 1. Unscrew and remove 3 crosshead screws shown below
Step 2. lift out entire unit as shown.
Step 3. With key in locked position remove Yellow part by pushing it down away from the key
Step 4. Move key to Open position. Using a thin instrument such as a sharp knife, push retaining wafer in towards barrel of lock.
Step 5. While holding retaining wafer in this position push the lock barrel out towards the key.
Step 6. Barrel is successfully removed. Wafers or springs will not fallout while key is in place.
Coding the lock barrel for your new key
Find a bright clean area to work on.
Slowly remove key from barrel. As you do this the wafers will pop out of their flush positions in the barrel.
There are 8 slots for wafers.
The 8th slot is used for the retaining wafer which holds the lock in place.
The 7th slot is not used.
The opening for each slot alternates between each side of the barrel.
Picture below shows how wafers and springs are placed in slots.
Picture below shows wafers removed from barrel with springs still in place.
Wafers are shown below with numbers. There are 3 different sizes, 1,2 and 3.
To recode the wafer:
Place the wafers you have randomly in the wafer slots.
Push the new key fully into the barrel. As you do this the wafers will move into the center of the barrel.
The wafers that are in the correct position will not protrude from barrel on either side of the barrel.
In the picture above wafers 5 and 6 are not flush with the barrel and are incorrect. Wafers 1,2,3 and 4 are flush and so will work.
Take note of the numbers that are in the correct position, and try different number wafers in the other positions to correctly identify the wafer numbers you require.
It is not necessary to have a wafer in every slot, although the more wafers you use, the more secure the lock will be.
In the above example all the wafers are flush. (Retaining wafer in slot 8 will never be flush) This is the barrel correctly coded for this key.
With the new key still in position refit the barrel to the panniers, reversing steps 1-6 above.
Go have a cuppa tea!
This is not a difficult task, but it is very fiddly.
Removing lock barrel from Pannier
Step 1. Unscrew and remove 3 crosshead screws shown below
Step 2. lift out entire unit as shown.
Step 3. With key in locked position remove Yellow part by pushing it down away from the key
Step 4. Move key to Open position. Using a thin instrument such as a sharp knife, push retaining wafer in towards barrel of lock.
Step 5. While holding retaining wafer in this position push the lock barrel out towards the key.
Step 6. Barrel is successfully removed. Wafers or springs will not fallout while key is in place.
Coding the lock barrel for your new key
Find a bright clean area to work on.
Slowly remove key from barrel. As you do this the wafers will pop out of their flush positions in the barrel.
There are 8 slots for wafers.
The 8th slot is used for the retaining wafer which holds the lock in place.
The 7th slot is not used.
The opening for each slot alternates between each side of the barrel.
Picture below shows how wafers and springs are placed in slots.
Picture below shows wafers removed from barrel with springs still in place.
Wafers are shown below with numbers. There are 3 different sizes, 1,2 and 3.
To recode the wafer:
Place the wafers you have randomly in the wafer slots.
Push the new key fully into the barrel. As you do this the wafers will move into the center of the barrel.
The wafers that are in the correct position will not protrude from barrel on either side of the barrel.
In the picture above wafers 5 and 6 are not flush with the barrel and are incorrect. Wafers 1,2,3 and 4 are flush and so will work.
Take note of the numbers that are in the correct position, and try different number wafers in the other positions to correctly identify the wafer numbers you require.
It is not necessary to have a wafer in every slot, although the more wafers you use, the more secure the lock will be.
In the above example all the wafers are flush. (Retaining wafer in slot 8 will never be flush) This is the barrel correctly coded for this key.
With the new key still in position refit the barrel to the panniers, reversing steps 1-6 above.
Go have a cuppa tea!
