KTM pannier lock repair

[@carver7689]

I'm having this problem with the right-side pannier on mine, and this video is a big help. I really like these OEM cases, but the chintzy plastic locks could have been done better. Thanks for posting this video!

[@lbjgh]

Glad it helped

[@aaronbenson3958]

Just bought a 1190 adventure yesterday with the bags stuck on, Thanks for posting this video. saved me lots of time!

[@lbjgh]

You're welcome. I'm glad the video helped.

[@lbjgh]

@FITNESSOVER45 sorry I don’t know the part number. I’d suggest you go to www.advrider.com forum and ask if anyone can help with the part

[@ricksteele7401]

Thank you for taking the time to document this process. I have already had my left side case replaced under warranty due to this failure. I am now faced with replacing a damaged right side case. I found a used case on E-Bay for a reasonable price and although the case is currently unlocked, there are no keys for it. Thanks to you and your video I was able to determine that I can access the lock tumbler and transfer my lock from the damaged case to the replacement. You really made my day clearing this up! Also, don't sweat the video quality, it was more than adequate to document what needs to be done. Thank you again!

[@Lewiseyers]

Rick Steele I just brought new set today, are the worth owning..I'm going touring

[@motorpsych]

Thanks again for the video. You are a trailblazer who allayed all of my frustration with this pannier that had a stripped screw in the lock tumbler. I put in a slightly longer screw and Loctite and it's great now.

[@lbjgh]

Glad to have helped

[@jimmurdoch6206]

Great video, I am now no longer totally entering the dreaded KTM unknown. Very useful, thanks for your time and effort.

[@lbjgh]

You're welcome.

[@lbjgh]

@FITNESSOVER45 sorry I don’t know if there is a part number for it. Do you know anyone with a 3d printer? Scan and print a new one. Just a thought

[@emfl4437]

Thank for the video. I have a KTM top case and the lock is not working. Going to take apart the lock this weekend

[@sorel93]

Great video! I'll give this a try.

[@lbjgh]

Good luck with the fox

[@CovertSolutions]

Thank you for posting. My lock failed and I followed your instructions. The small screw had come loose. Very poor design for such an expensive item.

[@lbjgh]

Glad to have helped.

[@CMA90]

Hi, what is the size of the screw? Or what type of screw is it? Mine is also missing

[@lbjgh]

@@CMA90 sorry I don't know the size. If it's missing I'd take the lock assembly to a specialty fastener supplier and get the appropriate screw by test fitting.

[@davidcoultrip4553]

Excellent vid helped no end

[@MrKromy67]

Thanks a lot for the video. I dropped my bike and the case detached from the bracket breaking the lock mechanism. Now I know it can be disassembled and I just need to find out if the part is available. Your video are just fine. Videos not need to be fancy just effective.

[@cyclingkk]

My lock is free moving left to right but it doesn't do anything. I'll have to take mine apart as well. I do wonder if it's possible to have a locked case where the key is free moving? That is, is there a scenario where I won't be able to get inside the case to remove all the screws?

[@lbjgh]

I guess that is a possibility Keith. if I was in that situation I would likely pry the pannier away from the mounting bracket at the front of the pannier and take my chances that the mounting screws wouldn't strip out of the plastic. Since I made this video I've installed the floating pannier mounting system and had the free pannier locking mechanism upgraded by the dealership. good luck

[@RunicSentry]

I'm in this exact situation. My top case won't unlock and seems to be stuck in the remove position. So I have the case off the bike but can't open it. Unfortunately, there are some leftovers from Sunday's ride in there besides my manual and toolkit. Anybody have any ideas on how to unlock it without destroying the case or mechanism?

[@TheGavrilaN]

Hi! How did you solve it? The left case is closed, locked on the bike. The key are rotating with no influence about the unlocking. So, I have no access inside...

[@PerhapsNoodle]

Keith, how did you resolve this? My left side case is locked and the cylinder turns with no resistance. Unable to get the case open or get it off of the bike. I'm going to attempt to knock the flat metal clasps off of the pins to get it open, I can't think of any other way but to cut the door hinges off or cut the case off at the rear plastic part. I cannot find anyone saying that you can get replacement parts, so there goes $600.

[@PerhapsNoodle]

I never was able to non-destructively get into my case. I brought it to a locksmith who made a sacrificial key and yanked the cylinder out of the forged black aluminum surround, cracking it. KTM of course does not make this part so they had to weld it back together, repaint, etc. I asked them why they didn't just drill it out and they claimed it wouldn't have worked. Needless to say, if you have these cases, it's highly advised to take them apart, even if they are brand new--and apply Loctite to the screw on the back of the lock cylinder.

[@killamv1]

Great video. My bike was blown over and the lock mechanism broke when the bag detaches. I was able to pull everything apart and fix with JB Weld. These panniers are so poorly and cheaply made. Not very robust and KTM should be embarrassed to use something of such low quality. I replaced them with Tusk panniers and racks that were about $400 complete and I can now use soft bags with the racks if I am traveling a lot off road.

[@Loudpedal10]

Thanks for posting I'm about to undertake the same thing.

[@lbjgh]

You're welcome. It's not a difficult repair. Removing the screws is the most difficult part of the project. Do yourself a favour and rig up the torx driver extension. The small tool in your tool kit will increase difficult significantly.

[@simonlewin7567]

Also how did you adjust the case lids to they shut so well? I'd be interested to know...

[@lbjgh]

I did a little twisting of the lids so the locks and latches lined up then adjusted the silver lock mounting points. They screw up and down.

[@davidnewton7405]

@@lbjgh Can you show how you did that? I"m a visual person. Sorry.

[@lbjgh]

David Newton since I created this video KTM released a lock update kit. It resolves any issue with closing the panniers. Details here: advrider.com/f/threads/ktm-1190-panniers-mod-to-make-them-close-lock-without-force.1121690/#post-30596079

[@wm7611]

Is it possible to remove the locks whitout removing everything.

[@lbjgh]

Good question... Likely not as there is a locking tab that needs to be pressed in to remove the tumbler. I suspect when the panniers are delivered the locks are left loose, rekeyed then popped into place which can be done without tearing everything apart.

[@wm7611]

Thankyou for the video. I also found an instruction of ktm called : Information PowerParts 60312924000 60312925000 Google it for those ho are searching for an how to.

[@lbjgh]

Yes there is a way to remove the lock tumbler with a curved pick. Have a look at www.advrider.com

[@cmlago]

Muy buen video. Muy útil!! Gracias

[@lbjgh]

den nada

[@nimoconst]

I've got the same issue on my 2015 . absolute crap of luggage

[@lbjgh]

I actually like the capacity and function of the panniers when the lock works.

[@lbjgh]

Good luck. Hope the video helps.

[@Lewiseyers]

so is there a specific part that fails, if so how regular as I'm going abroad touring.. .I've just brought a are new set... are the locks reliable

[@lbjgh]

I haven't had any issues with the locks or pannier since I posted this repair video. That was over a year ago.

[@Lewiseyers]

L BJGH thanks for putting my mind at rest..I've book marked your video just incase.. cracking video

[@Andrunk317]

Mine failed! The lock failed and would turn with no resistance. I had to take the box apart to get it off my bike. Once I had it apart I noticed the little screw and lock washer had come out of the back of the locking mechanism. I put the screw back in while having the lock in the locked position, and put the box back together. I'm sure I'll be doing it again at some point as I didn't put any loctite on the screw. So, I'm sure it will work itself out again.