Hi All,
As I have seen with other threads, I don't want to deactivate the locks, I want to remove the key when they are unlocked but still be able to lock them. And the answer is fairly simple.
First you need to understand how the key does it's work. There is an outside casing which has two cut-outs on opposite sides on the inside of the casing. There is also a hollow tube, with wafers which can move up or down. The key is inserted into the tube and the wafers move up or down, utilising the empty area of the cut-outs. If you where to use the wrong key, the wafers would not all move into line with the outside of the inner tube, thereby sticking out into the hollow area and preventing you turning the key to unlock the pannier. When you turn the key a quarter turn, the pannier is unlocked. However, because there are no cut-outs at this position on the inside of the casing, the wafers cannot move up or down and therefore the key cannot be removed from the lock. This only happens at the neutral position, which also engages the lock.
Solution: create extra cut-outs on the inside of the casing at the 90 degree positions so that the wafers can move up or down when the key has been turned 90 degrees to unlock the panniers. You will then have a total of four cut-outs (in the form of a cross). To do this you need to remove the the lock from the case. This has been described in other threads. Thereafter remove the silver cover on the top of the lock. I used a small screwdriver and made turning movements to push the inside rim upwards. Ensure that the rim lies on a bit of rag etc so that it doesn't get scratched. There is a small raised level at the back next to the rim which you can use as leverage for the screwdriver. Do this for maximal half of the rim. This allows you to slightly raise the rim and slide it off the rest of the lock, leaving an untouched portion of the rim holding full strength for when you replace it. After this, insert the key in the lock and pull out the inside tube, being careful to keep the wafers in place. Take the outer casing and you will see the two cut-outs on the inside. The next step you can do yourself or have someone do for you. Two additional cut-outs need to be made (drilled) at 90 degree position from the original ones, being careful to leave the back end of the casing whole (about 1 millimetre at the end). Hereafter push the inside tube (and key) back in the casing. Turn it 90 degrees to confirm that you can remove the key (hold the end so that the tube stays in the casing). Take the key out and replace the silver cover. Use a small hammer to flatten the inside rim back to the original position. You can also purchase a replacement silver cover, if needed. Assemble the lock in the pannier again. Now you have a pannier which you can lock or leave unlocked.
Note: The conversations which suggest that you only need to remove the spring from the locking mechanism should be ignored as this prevents you locking the panniers.
Unfortunately I don't have any photo's of what I did, but hopefully the above is sufficiently explained.
Regards, Rene
