Saturday 9 September 2017

How to install side toolbox locks on bullet

Original lock sets (However I got a pair of SWISS branded locks, though from an original Royal Enfield spares shop)

My air-filter box lock has always been a nuisance, for as long as I could remember. It never opened or closed the way it should and I wasn't really patient with it either, while I operated it. So the end result was this.

The clip broke which keeps the air-filter box door shut.

The rusted clip has been through it all and finally gave up.

I had no other choice but to remove the remaining bit of the completely rusted lock and the nuts. The small Taparia plier I have in my toolkit got the job done without any fuss.

A small size plier is good enough to release the nut.

Once the lock is off the box, now was the time to find a replacement. So I just drove (?due to heavy rains the traffic has gotten crazy lately and my bike needs a thorough check-up before I put it to stop-n-go traffic!) to the Fixwell Royal Enfield spares shop at JC road. There seem to be 2 versions of the lock set; naturally one for the classic 350/500/newer models and one (thankfully!) for the older models like mine. The one they gave for my bullet was made by the SWISS brand and not Royal Enfield. When spares are manufactured by a third party rather than the manufacturer themselves are few signs that you my friend own a vintage motorcycle;)

A Set of 2 locks comes in a box. 

MRP on the box was 165 INR, and the store took 150 bucks. I was looking for just the clip which broke. But I forgot that we are living in the era of capitalism and we need to buy the whole lock set (of 2) and not just one tiny replacement clip anymore :/

Manufacturer details. So what you get are a set of 2 locks (with 2 flower washers and 2 nuts) and 2 keys.

Each lock kit has 3 parts (excluding the key).

The old clip which had broken on my bull was of much better quality (thicker and stronger) than the one in these new locks. So am not very sure of the life of these, if they are put to similar torture/use as the older ones.

Remove the nut and the washer, then put the lock from the outside in, aligning the notch with the groove on the side box cover (both visible in this pic)

A point to note while installing this is, the flower washer needs to be placed on the inside of the box and the petals (/teeth) should be facing up and away from the toolbox surface, i.e. towards the nut. This way, as you tighten the nut, the washer will flex to give the lock a firm grip without making it crack due to the pressure of tightening. So in simple terms, the sequence of items for the right-side toolbox should be like this:-

Nut > Flower Washer (teeth facing the nut) > Toolbox hole > Lock piece > Key!

The new lock is in place with the new key; gotta add *another* key to the bunch now! (eye roll)

Now as I said, the lock set was not from RE and hence there is some difference in its build quality compared to the original set of locks, which I replaced due to rusting/breakage. There is also a minor difference in the size/trim of the locking clips, which makes it a bit difficult to lock and unlock. For now, I have fitted them somehow with a few attempts and by bending the locking clip a little bit with the plier, but planning to get the edge of the clips trimmed a bit for a smoother and hassle-free fit. I will try and post an update here when I do that.

By the way, this lock replacement activity is part of my revival plans for my bull, which has been parked for more than six months now. Due to travel and work commitments, I haven't been able to ride it since February this year. And I am afraid if I leave it unmoved my (relatively) new front tire rubber might harden and that will be risky during a long trip. So I just decided to give it the much-needed attention and start working on it. The first step was to go out and shop for some spares and lubes. The next thing is to get the bike checked and serviced soon.


As of now, I could only get the bike cleaned and polished. Next is an oil and air filter change (along with fresh oil of course). As time permits will check the condition of the clutch and valves, before thinking of a long ride. The rear tire is also on the brim of replacement so gotta drop by the tire shop too. Probably will get a Michelin for the rear this time, as the front one has done so well in the last few trips. Until then.

After dusting and a bit of pampering.. awaiting a service soon.

Ride Safe & Ride Far, 


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