I’ve always had a love-hate relationship with Triumph and Givi, their cases, and their different barrels. It began when I tried to use the barrels from my new 2018 XCA on my old 2013 XC boxes. (cutting down and bending an old key ring holder to pick the lock in the riveted housing is no fun, success, but no fun)
Fast-forward to my new 2023 Tiger 1200 Rally Explorer and the latest key styles that I believe started in 2018.
A few weeks ago, I wanted to order a new set of barrels from Triumph. I aimed to re-key them to match the barrels that came with my bike. This would allow me six barrels, all keyed to my 2023 RE. It’s a bit overkill. The barrels only come in sets of three. An exception is ordering the set of two from a Rocket to re-key.
The intention is to buy some larger cases, in particular a 58L Givi top box, and use a newly formed Triumph barrel that has been rekeyed to use my factory key
Things you will likely need to complete this part of the project:
- Set of three randomly keyed lock barrels from Triumph – T2501889
- Random non-Triumph barrel off Amazon for extra parts if needed https://amzn.to/3YuXN4v
- New Triumph Top box replacement latch – A9500690
- New Givi 58L Top Box – https://amzn.to/4c1UaWU
I have three barrels, currently being used in the Triumph-branded side and top cases. One of the extra barrels would be used in a 58L Givi top case…assuming my engineering project would work. The other two keys would provide extra wafers for the rekey. They could also be extras for larger Givi side cases in the future.
We needed a quick lesson in rekeying the locks. We need to discuss the three main components in the barrels.
- The housing, which is a cast steel piece
- The numbered brass wafers that make up your key combination
- The tiny springs move the wafer up and down when the key is inserted.
It’s important to note that if you attempt to remove the key while it is outside the black barrel sleeve, your wafers and spring will go everywhere. However, you need to remove the key slowly as it holds the brass pins in place on the top and bottom.
Each wafer has a number on it. Write down the order.
The goal is to know your wafer order so it can be duplicated. This can be easier with someone else pulling the key out while you hold the top and bottom brass wafer in place. Then, slowly, allow each wafer to slide up and reveal its stamped number. It takes some practice. If you lose wafers or springs, you can order a few of these barrels from Amazon; they work as replacements.
https://amzn.to/3YuXN4v (This is NOT a Triumph barrel; use it for placement springs and wafers only)
Make your new barrels match the wafer order on your current Triumph barrel.
Once you have a matched barrel, the hard part is over.
- Remove the lock housing off the Givi box via the six screws inside the box
- Replace that lock housing with the new Triumph housing you bought – A9500690
- Put your new re-keyed barrel in that Triumph lock housing on the Givi box
To use a Triumph Top Box Mount, modify it slightly by drilling a few new holes and moving the plastic V clip back an inch or so. See how to do that here. – https://www.tiger-explorer.com/index.php/topic,20243.msg233527.html#msg233527