Multistrada 1200 / Ducati Luggage Locks – Setting a lock tumblers to suit a different key

Multistrada 1200 / Ducati Luggage Locks – Setting a lock tumblers to suit a different key

See also: Fitting locks to your panniers and/or topcase (topbox) – see video below
…and photo set here (to come)

Multistrada 1200 / MTS1200 – Setting a Pannier & Topcase (Topbox) lock tumblers to suit your key

By ‘Multi rider’ aka Fritz D (Apr 2013)

Last year I took a ride down to the Goodwood Festival of Speed and when i got there my left side pannier had disappeared….Don’t ask how???
It was locked, the handle was down, all I can think is that it had come loose as it was empty. The intention was to use it to store my helmet so I suppose one could say I was lucky, the other side had my laptop in it…. loosing that would have been a disaster!

I managed to get a new second hand pannier off fleabay but the gent that sold it to me wanted to keep the lock tumbler, so I was one step further but now I had a lock predicament…. ie I either bought a new set of tumblers from Ducati (£90-£100 for a set of 3), but I would have had to use 2 keys….. or I tried to get a single lock replacement form somewhere and set it to use my existing key.

Last week a very kind Dutch fellow sold me one from a 3 set he had bought but only needing two locks.

The question of course is…..How do you change the tumblers to fit a different key???
I did not want to have to use 2 or more different keys.

It can be done, this is the process but before I describe that…..
I am not a locksmith, have never done this before and have had to fiddle my way through working out what to do as I went!

I hope others can benefit from this but please don’t hold me responsible for any problems! 🙂

Getting Started!
Here is a picture of the tools I thought I would need.

It is important to work over a catch tray or similar, I used a medium sized Tupperware container and even then I almost lost one of the tiny springs!….be very very careful.  Good tweezers will help a lot.

(2) Start by “un-crimping” the lock cover, you will need a fair amount of “controlled” force to bend the crimping tabs back carefully so as not to damage the cap in such a way that it cannot be refitted….have a good breakfast 🙂

…note the two small springs 😉

(3) Once the cap / cover is off you will see the lock “slide protectors” little red slides that stop ingress of water and dirt. NB note the small springs that keep the slides shut. These small springs are different to the individual tumbler springs….don’t mix them up. Carefully remove all of this so that you can see the brass locking pin.


[AndyW] Some info that may help you understand the lock re-configuration process…

Components of a ‘wafer’ tumbler lock

The present invention is a wafer tumbler locking mechanism, generally referenced as 100, including a lock body, lock housing or shell 102, a lock cylinder 104, a set of spring-loaded wafer tumblers 106 and a set of spring-loaded sidebars 110. Optionally, the wafer lock may also include a cylinder door 118, cylinder door spring 120 and cylinder cap 122 which assemble into a cylinder plug 104 front opening 124. The cylinder cap 122 contains an opening 126 into which a key 130 is inserted.

Without a key in the lock, the wafers (red) are pushed down by springs. The wafers nestle into a groove in the lower part of the outer cylinder (green) preventing the plug (yellow) from rotating. When the correct key is inserted, the wafers (red) are raised up out of the lower groove in the outer cylinder, but not so high that they enter the upper groove in that cylinder.With the wafers unobstructed, the key, wafers, and plug (yellow) can rotate. 


(4) You can now carefully remove the locking pin from the tumbler by pushing it through the lock housing….very carefully, work over your catch tray (Tupperware container)!….the individual ‘wafers’ will fall out, sometimes the springs can pop out, sometimes they don’t and sometimes they fly out….be careful, very careful.

…otherwise you will need the brush and dustpan to sweep the floor and find the tiny little springs that have a mind of their own!

(5) The individual wafers are marked 1, 2 or 3. There is one wafer that has no marking. This is the one that goes on the end (furthest away from the key entrance) and stops the tumbler from pulling out of the plastic housing.

(6) Now you need to use a trial and error method to match the individual wafers to your key. I initially left the little springs out, and starting at the “key entrance” worked the individual wafers in to the housing, working toward the end with the square and little screw thread. Its fiddly, and you will need to try the different numbers in different positions. Number one is where the key has a central grove, and number three is where the deepest cut away is from the centre of the key.

Once you have the wafers in the correct sequence I would write the sequence down. Note there may be some empty positions in the sequence. Important is that when the key is inserted that all the wafers are pulled in and flush with the housing.

(7) Now that you know the sequence you can remove the wafers again, insert the little springs and using the key to hold the tumblers insert the locking pin.

(8) Re-install the little “Key entrance slide protectors” (little red thingy’s) paying careful attention to the little springs. Replace the cap / cover over the tumbler end and test the lock by inserting it into the black plastic holder.

The tumbler can go in in two ways but only one way will allow it to be flush with the plastic holder. This means the last wafer will engage into the plastic housing and will prevent the tumbler from being with drawn from the housing. To undo it, or to get the tumbler out of the housing, insert the key and with a watchmakers screwdriver, gently push the last wafer into the housing from the “end with the square and screw thread”. The key and tumbler should now release from the black housing.

(9) Crimp the chrome cap / cover back onto the tumbler housing. I used a vice as you can see here.

Don’t put the tumbler on the naked vice face as I have done, it leaves marks (twit that I am) and possibly use a punch rather than a screw driver to tap the crimps closed.

Installation / fitting the whole lock assembly into the pannier can be seen here!

The whole process probably took me an hour, its fiddly and you need patience but at least I will only be using my one master key and will not need to carry two keys with me.

I hope this helps you, should you have any questions feel free to contact me via the Ducati UK Forum

Good luck and all the best!

  • Phil Womack says:

    Very very useful post thank you. I bought a Multi with panniers and wanted to add the matching topbox. The spare lock barrel didn’t come with the bike but I thought I could just buy one off Givi. I handed over a truly extortionate amount of money to Ducati and the box arrived. This is when I discovered the locks are different. Scouring the forums I discovered that a KTM lock barrel was made by the same Spanish company that supplied Ducati. Another extortionate amount of money later and thanks to this post I have a matched barrel to my original key. Thanks again

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