Step-by-step photo tutorial: rekeying BMW case locks

Rekeying BMW case

Or how to modify/rekey BMW case lock to match the desired key

Now, who wouldn’t love these DIY tutorials? You simply can’t get enough of them on the internet, especially good ones. This detailed photo tutorial of rekeying BMW case lock is the first post in our workshop category, and we’re so excited to show it to you.

A lot of our friends approached us with this question – how do I change my BMW case lock to match my desired key? Well, it’s probably a lot easier than you think and it sure is handy to have only one key for all the locks on your bike, especially during motorcycle trips. And you shouldn’t worry about anything going wrong, because we did this quite a few times and it’s a safe method. Now let’s get our hands dirty.

Part 1 – Start here if you have a used case and want to rekey it so it fits your desired key. If you have a new case with the lock ready to be rekeyed, then scroll down to part 2 of this post.

1. Open the case and start by removing three Philips screws on the inside of the lid (screws are marked with red circles on the first photo):

Rekeying BMW case 1

2. Let’s have a closer look at the first screw:

Rekeying-BMW-case_2

3. The second screw:

Rekeying-BMW-case_3

4. And the third one:

Rekeying-BMW-case_4

5. With screws removed, carefully lift out the latch mechanism panel:

Rekeying-BMW-case_5

6. On the backside of the latch panel, make sure that you can see the round yellow tab that locks the handle:

Rekeying-BMW-case_6

7. Carefully remove the yellow tab using a knife or some other thin metal tool:

Rekeying-BMW-case_7

8. Now you can see a small metal tab which keeps the lock from coming out:

Rekeying-BMW-case_8

9. Now put the key in the lock and use a knife again to depress the tab and gently pull out the lock with your fingers:

Rekeying-BMW-case_9

10. You should be able to easily pull the lock all the way out. With the key previously inserted, you’ve made sure that the tumblers stay in place for now:

Rekeying-BMW-case_10

Part 2 – Continue through these steps if you’ve followed all the ones described above. Start from here if you have a new BMW case with a lock ready to be rekeyed.

11. To continue this process you might need some additional tumblers (depending on the key). You can get them at the nearest BMW dealer. If you bought a new lock, first make sure that you throw the manual into thrash. Unfortunately, it’s useless. Now you may continue. Unpack the contents and sort the tumblers (sometimes called followers) in their numerical order (they are all marked with a different number). Make sure that you always know which one is the latching tumbler (sometimes called drill out protection or stop plate). In the photo below it’s in the topmost right position, between the lock and the key. You’ll notice how similar it is to the Greek letter ‘’Pi’’.
As we’ve already mentioned, all the tumblers are numbered, but there are only three types (numbers) – 1, 2, and 3. Plus the latching tumbler which you have only one so be careful not to lose it:

Rekeying-BMW-case_11

12. First, insert little springs (pressure springs) into round holes as shown. Before you do this, it’s recommended to apply a small amount of lubricant to the cylinder:

Rekeying-BMW-case_12

13. As you can see, there are 8 slots in the lock cylinder. The first one (topmost on photo) is the one for the special, latching tumbler (or stop plate). Pay attention that the slot next to the latching tumbler’s one (the second from above on photo) STAYS EMPTY! And that means no tumbler and no spring in this one. Now make sure that you have inserted the springs and the tumblers in all the other slots (don’t bother with the numbers for now). The picture below shows where to put the latching tumbler:

Rekeying-BMW-case_13

14. Now insert your desired key into the lock. Have a look at the lock from the side, and check which of tumblers are protruding out. You’ll probably see something as shown on the photo below. What you have to do now, is to replace the protruding tumblers (ones that didn’t go all the way in) with the ones that have a different number engraved. Pull out the key and replace them. The ones that were all the way in with the key inserted should stay in their slots. Feel free to play around until all of them fit in perfectly, while the key is in the lock. Remember that the only one that should peep out is the latching tumbler!

Rekeying-BMW-case_14

15. Keep in mind that the left one is the latching tumbler and it should peep out a little. The slot next to it is empty. When you succeed, your lock will look like the one shown on the photo below:

Rekeying-BMW-case_15

Part 3 – putting the lock back into its place and assembling the case back into its original state.

16. With the key inserted, push the lock back into the barrel. You’ll have to give it a 180 rotation, so it can go all the way in:

Rekeying BMW case 16

17. You should hear a ‘’click’’ sound which means that the special latching tumbler is in right place, and the lock fits perfectly:

Rekeying-BMW-case_17

18. Try pulling out the key. If you can’t do this, then you’ve probably inserted a tumbler into the slot that should remain empty. If that’s so, then go through step 9, and empty the slot (the one next to latching tumbler).

Rekeying-BMW-case_18

19. When the lock is rekeyed, be sure to put back into place the yellow tab from steps 6 and 7, and then screw in the 3 screws and you’re done!

Rekeying-BMW-case_19

Congratulations! You have mastered the art of rekeying BMW case locks. We hope that it didn’t take you too long and that it was worth it. Feel free to ask any questions, we’ll be glad to help. If you have any suggestions for our workshop category, than shoot in the comments section and we’ll make a note. We hope that this was helpful and stay tuned for more.

98 Responses to Step-by-step photo tutorial: rekeying BMW case locks

  1. Jim Gurney says:

    Great tutorial for re-keying BMW case locks! I sold my 800GS and swapped my top case over to my 2012 1200GS. You saved me a trip to the dealer and a few bucks too. Thanks.

  2. Rob says:

    Great instructions – many thanks for this. Looking at BMW instructions nearly took kits to dealer but luckily found this article – way better! My tip would be to insert key each time you add a dropper to test it as you go. Cheers, RB.

    • Hi Rob; thanks for you feedback, happy to help! Also, thanks for the small hint; definitely a good suggestion is to test the result with a key every time. Cheers! Darko Novosel

  3. stewart says:

    Just fitted new barrel to my new top box using your tutorial, but unfortunately i put an extra tumbler in when I shouldnt have. I was wondering if anyone knows how to get the barrel out of my top box, its a 49ltr style for my k1300. Bmw dont know, which I find very unusual, they werent much help at all.
    Thanks,

  4. stewart says:

    Hi Mototrip team,

    I have said that I built up a barrel using your tutorial, I accidently put an extra tumbler in when I realised I shouldnt have, but I need to get the barrel back out of the top box so I can get it to work properly, but Bmw dont know how to release the barrel from it housing inside without damage, so have you any Idea’s how to. Its a Bmw top box the 49ltr one.

    Thanks, Stewart.

    • Hi Stewart, hopefully you managed to work it out. If not, please send us an e-mail (available from our website) with a picture and we’ll do our best to explain how to do it (if possible). Greetings, Darko

  5. Dale says:

    Another thanks for the instructions. Just rekeyed a top case that I got from a friend for my 1200GS. It was a snap. I was able to use most of the followers from the old case but needed one more that I got from my dealer (they happened to have an extra set laying around when I went in).

  6. Sky says:

    Great guide! These pics are a bit different than the lock setup I have on my 2001 F650gs but its a very similar procedure for replacing the lock/lock cylinder on the top luggage cover. Thanks!

  7. Kern says:

    If you use the followers from your old key and just “leave out” the followers that don’t work, will the new key still work? And, would that allow the old key to work as well? I am moving a Vario top case from my wife’s 1200 GS to mine. I thought it would be cool if both keys worked, even if that increases my chance of a third party’s key working in the top box. It’s not BMW riders that worry me when I lock a case.

    • Hi Kern; I do believe it would work; but do try it out yourself. Although like you mentioned, it could be easier to open the case with a 3rd party key- good to have in mind when travelling. Not saying anything against BMW riders as I’m one of us, but always be careful.

  8. Graham says:

    Very concise tutorial. Many thanks. Only difference was the way to remove the barrel from the case on my K75RT Ultima panniers. Other than that excellent.

  9. Ed says:

    I purchased a pair of used vario cases. I don’t have the original key. Is it still possible to remove the tumbler with my BMW key from my bike?

  10. Steve Hyde says:

    I have a GS case I bought on UKGSER and need to code the locks, some months ago I successfully did the top lock which locks the lid down, now I need to code the one that locks it to the rack.

    I have got the tumblers such that they are all flush with the barrel when the key is inserted. Except the retaining one.

    The lock easily fits into the lock and turns, but I cannot remove the key whether its in the locked or unlocked position. As soon as I pull it out of the cylinder the key is freed.

    Where have I gone wrong ?

  11. Steve Hyde says:

    problem solved, I hadn’t left out the tumbler next to the latching one.

    Thanks for the information.

  12. John Anderson says:

    Great instructions!
    After fitting a barrel into my new Alu top box for my F800GS Adventure, I realised I had added too many tumblers, and once in place the lock and barrel jammed in place with the key not being able to lock it!
    Now the problem…getting the lock cylinder out again!
    To do this I adapted a very thin flat head screwdriver, by bending the last 100mm at a right angle. I was able to release the latching tumbler with this by pressing it in whilst gently pulling and wiggling the key and cylinder out again. Phew!
    No embarrassing trips to the BMW dealer asking for help!

  13. Wombat Mobile says:

    Do you know how to remove the aluminium facia plates from the side of the pannier? Mine is dented. I would like to remove it and straighten it out, but can’t work out how it clamps on/off. Thank you for any help you can suggest.

    • Hi there! You will need to loosen the upper and lower frames that are holdin it; and after you gently ‘peal’ them off. They are glued so take your time/be patient. Hope it works!

  14. Andy Adams says:

    Excellent instructions, just fitted loose locks into my new vario cases on my 14plate r1200Gs.

    Thank you

  15. GRAHAM says:

    Hiya, l dont think l can open my BMW Sport panniers now I’ve lost the key. Is that correct or is there a way to get into them ?
    thank you
    gb

    • Hi Graham, thanks for your question. Unfortunately, we cannot help you with opening cases without having the right key; it would be the best to visit a BMW Motorrad service and ask for advice.

  16. Richard says:

    Hi
    I have remove the locks from my BMW sport cases. I want to change 1 tumbler, but cannot remove any of them, they do not slide out and feel like they are retained by something. Before I use more force is there something I am missing or not doing?

    Thanks

      • Richard says:

        On both locks with the keys removed the tumblers feel secured in place. I did try and push out with a thin bladed screwdriver but held short of applying too much force. I could remove the end or stop tumbler but that was it

      • Strange; what exact model year is that? We haven’t tried with new R1200GS (2013+) locks, could be something different? When we remove the key, all tumblers are very easy to remove, almost on their own.

  17. Richard says:

    Found the solution. On the sport case lock you need to prise of the chrome cover and underneath is a pin that stops the tumblers releasing. Need to be careful as there are two spring loaded plastic sliders under the chrome cover that close the key slot when the key is withdrawn.

    • Thanks for the feedback Richard. I did not know sport cases were configured differently; but do now. Hope this will help to someone else too. Happy you solved the problem, ride safe.

  18. Dave Leslie says:

    Many thanks for this excellent tutorial. It has made keying all three boxes an absolute breeze. From Dave a happy GS 1200 rider.

  19. Jim Canning says:

    I’ve been putting off, for ages, trying to key the top box from my last 1200GS to match my newer one. Took 10 minutes to do, following your clear instructions. Thank you!

  20. Rob says:

    Hi,
    I’m looking at a second hand top box that will fit my F800ST, the seller can not get the key out of the barrel. Can you offer a suggestion, the key opens everything and works but appears to be stuck??
    Please help.
    Thanks
    Rob

  21. Tim says:

    Great instructions
    My problem is I cant remove the key from the lock
    Ive done every thing I can think of.
    Help please
    I can get it out by depressing the retainer from the inside of the lock
    Its a new barrel for a new 2nd hand box.

    • Hi Tim,

      thanks for your question!
      Try pulling the lock out (with the key) and make sure that the 2nd to last tumbler is not inserted; that’s the most common ‘mistake’. If it’s in, remove it from the lock and it will work.
      Keep us posted,

      Darko

  22. Conn Grant says:

    Thanks for this

    Really liked the simple instructions… I’m now a recoding genius! :) (Maybe not!)

    Saved having dealer do this for me at cost.

    Keep up th egood work!

    Conn

  23. Stewart Johnson says:

    I have a new style 49l on a 2008 k1200gt case and the key is stuck in the case with no possibility of getting it out as the extra tumbler was installed.
    I would appreciate any suggestions very much!
    Thanks

    • Hi Stewart!
      You’ll need to get the lock out from its housing; you’ll need to do that by pressing the tumbler from inside the case with a knife or something thin. Once you have the lock out, remove the key and the extra tumbler you don’t need. Hope that helps.

  24. Chas says:

    Step 9. states: “Now put the key in the lock and use a knife again to depress the tab and gently pull out the lock with your fingers”

    If the current case lock key is not available, can the ignition key (i.e. the key I want to rekey the lock to) be used for this step? In other words, is the current case lock key required to remove the lock on an unlocked case?

    • Hi; good question. My guess is no, but it’s easy to try. New key will make the tumblers pop out, which I do believe will prevent you from pulling it out.

  25. Alexandre junqueira says:

    Thank you
    Great tutorial.
    I’ve just bought an 1200gs and its cases locks aren’t working. I guess the old owner bought the cases from another person and it was the combination key of another bike.
    Followed the instructions and I was able to dissambly and save the cases – now everything works 😉 … Just a matter of recombine the tumblers and it worked.
    Btw using other key to remove the locker works (at least for me) even white tumblers popped out.
    10 minutes and done.

  26. Hossain says:

    This was amazing. Such good and clear instructions.

    The BMW provided ones were useless.

    Thank you so much!

  27. Bert Lee says:

    Very helpful instructions. Just re-keyed my just received used Vario top box and this was the perfect find. After swapping things around I actually reused all five that were in the cylinder. Working perfetly. Thank you very much for posting!

  28. Axel says:

    Hi, I just bought a used nav5 cradle with the lock cylinder removed by the PO. For some reason I can’t remove the tumblers. Do you have any idea if there’s a locking pin or something in the new LC locks? I’m planning to key it to a 2012 GSA.

    • If the key is inside while you’re trying to remove the tumblers, that’s the reason. Otherwise, tumblers should go out very easy (except for the locking one- you need to pull it out). I hope that helps, regards!

  29. Si Kusners says:

    Hi,
    The previous owner of my panniers had rekeyed them to his bike key, so I don’t have the original key, is it possible to remove the lock without the original key?

    Cheers,
    Si

  30. kevin.griffiths97@ntlworld.com says:

    Good tutorial, had no problem sorted in 15mins.
    Don’t let bmw tell you you need the original key, as long as you have a key the barrel is easily removed.

  31. Rick Trengove says:

    Great article.
    Bought used Vario topbox which came with a key. Recoded to suit my ignition key.
    Only problem lock that was fitted to box didn’t have any #1 tumblers. I fitted it missing three tumblers and it works a treat. Probably not as secure but better than nowt. Now got 2 off #3 and 1 off #2 tumblers. Anybody know if there’s a swap site? I need 3 off #1

    • Hi Rick, glad it help. You’re right, the lock can work without certain tumblers, but it’s not as secure. Looking online, BMW doesn’t sell the tumblers separately; they come with a lock. I personally have a bunch extra ones I don’t need, so if you’ll be passing by Croatia, let me know :) Otherwise, try asking at your local BMW Motorrad service, they could have extras too.

  32. bill mier says:

    Hi . thanks for the great tutorial.
    I have two adventure aluminium cases fitted to my R1200gs. I’d like to key them the same as my ignition key. Three locks per case.
    Can i do this using your great tutorial?
    Thanks!

  33. Brian Farrerlly says:

    Used the tutorial to rekey the locks on a full set of BMW Vario boxes today and it seemed much easier than when we had to key a new set of locks for the same boxes in 2016. Many thanks, Brian.

  34. Stefan says:

    Awesome instructions.
    All worked well.
    You deserve an award.
    Thank you so much for the effort putting this together.
    Cheers
    Stefan

  35. John says:

    Thanks for the instructions, earlier in December I used your instructions to rekey the Vario side cases for my 2019 r1250gs, finally found a Vario topcase on CL so just rekeyed using your instructions ! Thanks for saving me so much time!

  36. Bret Moye says:

    Darko,
    Thanks for the tutorial. I switched out my cases and realigned tumblers and removed one so now the lock works on the different bike. saved me time and money.
    I owe you a Rakija. :)
    Cheers, till we ride again,
    Bret

    • Hi Dean,

      thanks for comment. This is the number for the pack that includes the cylinder, pins and springs: 51 25 7 698 202. It’s for a BMW R1200GS stock vario case. I believe you can’t buy the pins separately unless you find them used somewhere on eBay.
      Hope that helps, let me know. Regards,
      Darko

  37. Des North says:

    Does this work if you only have they to the bike you’re re-keying the lock to, and don’t have the correct key?
    Thanks

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