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7. Now drill a 3.5 mm hole completely through the key blade using the mark left by the 2
mm drill.
8. Replace the fillet onto the key blade and cut any excess
metal beyond the fillet (see photo left). The key will then be
as photo right. Use a file or bench grinder to remove any
burrs from the drilled hole or end of the key.
9. The photo to the left shows the remote control split open with the fillet over the key
blade and the sleeve nut fitted into the remote upper casing. When assembled the
3.5mm hole in the key blade goes over the sleeve nut, the two case halves are clipped
together and held via the small countersunk set screw into the sleeve nut.
9. If you are converting a transponder type key the chip is located into the upper case
half in the area indicated. There are two main types of transponder chips used in
motorcycle transponder immobilisers the glass bead type and the flat semi rectangular
type. Their position within the remote is shown in the photos shown below. A bead of
silicone sealant is the best way to secure the chip within the housing.
Glass bead type
transponder chip in
position
Rectangular type
transponder in position
10. The finished converted remote/key conversion should look like this. Should you
have cut the key width a little small, a good two part glue can be used to fill in the gap.
Warning:
Suzuki and Yamaha ‘cranked’ keys can be converted but do not cut the key
straight. Instead use the fillet on the cranked section which was within the plastic
section. The key will be offset to one side in the finished conversion. We would
normally advise the customer to purchase a ‘normal’ replacement key so the finished
conversion leaves the ignition key central within the conversion.
11. This photo shows the finished conversion within the ignition barrel. Recheck the
ignition and steering locks all work correctly and the machine starts if a transponder chip
has been fitted into the remote. It is not advised to fit the lanyard supplied with the alarm
kit to the key if the conversion has been carried out.
The key conversion is not a part of the standard installation and the level of charge to the customer is at the dealer’s
discretion.
