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Discussion Starter · #1 ·
Actually the Burgman 400 is my wife's (Stephanie's) bike, and I'm trying to help her get info on how to replace her
programmable key, or possibly R & R a New ignition, whichever is more feasible.

1st question: W
e stored the Burgman with the front wheel in locked position, and the 'shutter' closed on the ignition, so do both the front wheel and the shutter only unlock with a programmed key? (We have a flat, non-programmed spare key, but it is useless with the ignition shutter in place).

Could someone out there give us the answer to this question, and perhaps recommend a solution or some choices?
Thank You very much! (Stephanie has been looking forward to riding her Burgman again for the past 7 months,
and I'm the one who locked it up, although she lost the key! (I just hired a professional 'food taster' to avoid being poisoned. lol). Thank You for any answers and suggestions! Doug Cabell
 

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Discussion Starter · #2 ·
Actually the Burgman 400 is my wife's (Stephanie's) bike, and I'm trying to help her get info on how to replace her
programmable key, or possibly R & R a New ignition, whichever is more feasible.

1st question: We stored the Burgman with the front wheel in locked position, and the 'shutter' closed on the ignition, so do both the front wheel and the shutter only unlock with a programmed key? (We have a flat, non-programmed spare key, but it is useless with the ignition shutter in place).

Could someone out there give us the answer to this question, and perhaps recommend a solution or some choices?
Thank You very much! (Stephanie has been looking forward to riding her Burgman again for the past 7 months,
and I'm the one who locked it up, although she lost the key! (I just hired a professional 'food taster' to avoid being poisoned. lol). Thank You for any answers and suggestions! Doug Cabell
P.S. We are willing to disable the ignition shutter, but think we may still need to get a programmable key (or new ignition)
to unlock the front wheel??)
 

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Doug, if you take the ignition shutter apart you should be able to open it up. Then the new key, if cut right will unlock the front wheel and start the bike. But the key must be cut right. It has a shoulder that must be ground down to the same size as the uncut tumbler section.

No 'USA' Burgman's that I know have security chips. Just the 3 magnets in the head coded to the shutter.
 
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Discussion Starter · #6 ·
Why not just get a new key from Suzuki or are they really expensive?
To Bigmc: Yes, thanks! We're going to call the Suzuki dealers in the Volusia County area on Monday, Jan. 16, 2023 to check details and pricing. Hopefully, we can get a new programmed key without taking the bike there (one person in 'service' thought they needed the scooter to program the key (scooter is really not very transportable on a trailer with a locked front wheel).
 

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I always make sure I have 2 keys for any vehicle I buy...
and service manuals! Swmbo keeps the spare key in a safe place
(she was kinda lumpy lookin on the left one there for a while till we sold the used car lot)
 
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The dealer will not sell you a spare key capable of operating the shutter door, just a plain/flat metal/uncut one ?, the only solution they will offer and that will restore scooter to normal is to replace the "Lock Set" possibly around $600+ with labor :unsure:. Cheap solution is to have a good locksmith disable shutter (or DIY) and make a key, around $100-200 depending on amount of disassembly required, etc. BTW, is virtually impossible to arrange/know magnets positioning on a Chinese key clone of Ebay, without the original key as a sample. :( Just out curiosity/challenge, I'm going to order a Ebay key to see if it can be done :unsure:. Wish I was a little closer and not so busy this week, I would come over and give you a hand with this or bring it over. IAC, Good luck.
 

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I swear I'm not trying to gloat, not rub it in, and that I'm trying not to be a jerk. I just offer this for others, for future reference, for what it's worth, and so forth: after the initial playing around with the shutter gizmo on my first Exec, to see how it worked, I never closed the shutter, or locked forks, or any of that kind of stuff, on either of the two Execs I owned for a total of 11 years (or any other bikes).

I felt that it was asking for trouble -- for me, the owner -- to screw around with such trickery, because it's just something that can malfunction, and it would be me who couldn't start the bike. If someone's going to steal a bike, they're going to steal it. You can look at YouTube videos on how easy it is snap fork locks, or for people to cart away a bike in a van, and so forth. When I sold my latest Exec, I specifically mentioned that I did not play with the shutter, and only put the key in one of two positions (on or off), and recommended to the new owner that he do the same, i.e., no getting cute.

This is what insurance is for. If you want, maybe in a sketchy area out of town: a disk lock with alert-to-you cable and maybe a bike cover. A long time ago, I dispensed with both, and the most I ever did on trips was ask hotel management if I could park under the entrance awning type of thing (which was both for a little more security, and to keep the bike out of the rain).
 

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The moral of the story is if you purchase a vehicle with one key, take care of it immediately. These are the spare keys that came with my 99 BMW. A total of 6. The one I use and one of those short keys I keep in the seat release lock assembly under the rear taillight. No one can see it since it is so short.
 

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I always make sure I have 2 keys for any vehicle I buy...
My '22 C 400 GT came from the factory with only one fob (which I think is par for the course these days, for bikes -- for our last new car, five+ years ago, we got two fobs).

I put an AirTag on the key ring for that bike: fob, house key, and now the Apple gizmo. A little bulky in a pocket, but I think that's the best I can do.
 

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If you have the "blade key" to replicate from then go ahead and buy a pair of magnet type keys from ebay. (Link) (about $6 to $8)
The magnet pattern can be discovered by offering up the magnets to the lock shutter. (Allegedly!)

This instruction cribbed from a YouTube comment.

1. Take all magnets, colour one side of each only using any coloured sketch sharpie.
2. Stick them in to the lock and identify the colour position (For checking north and south pole) then fit it back correctly in the duplicate key

Rectangle Font Screenshot Parallel Number

(Edit to add image)
 

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I just ordered a few oem type magnet keys from Amazon, should be here in 4-6 days, all others on Ebay, were the "Slow boat from China" or 30 days o_O to USA. Wil make 2 fully working duplicates, going to see if using shutter reference is possible, I not sure if the magnets in key are positioned to pull or repel the ones is shutter :unsure: will know next week, maybe :rolleyes::whistle:
 

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I think the magnets that come loose with a new key will stick to the 3 magnets in the shutter.

So, stick them on and note which side is facing out. Like said above, mark the sticking out ones with black sharpie. The press the sharpie side IN OUT into the holes of the the new key.

Edited per comments a few posts down.
 
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Has anyone checked with a dealer about replacements?
Suzuki does not sell the magnetic shutter key blank by itself, just flat metal blanks, that need to be cut to match oem key or to a key code. In either case is done by a dealer (that's capable, not all are!) or a locksmith.
You can only buy aftermarket clones with the magnet head, that you must DIY the correct magnet placement and cut to fit.
 

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I think the magnets that come loose with a new key will stick to the 3 magnets in the shutter. So, stick them on and note which side is facing out. Like said mark the sticking out ones with black sharpie. The press the sharpie side IN the new key.
will that always work? or are some of them pushmepullyou types?
 

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