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Lost my 2009 Burgman 400 original key!

4192 Views 26 Replies 11 Participants Last post by  nulldevice
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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Inside the shutter are 3 magnets faced in the key "CODE". These 3 magnets pull PUSH 3 small steel balls out of dimples and allows the shutter to turn.

In the key's head are 3 magnets facing the opposite SAME way for the code.

Edited for comment in post below.
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I tested magnet polarity with a small pen magnet, then inserted key head with very light pressure, kind of floated in place, did this in both open/close positions, it appears as magnets are opposite pole, key is pushing out/falls off :unsure:, if the magnets were pulling at each other key would stay in place. I also lifted a 1/4oz with each individual magnet easily.
IOW they have a strong pull. This is unofficial, until more scientific testing and verification is done, just preliminary "Thesis" findings :rolleyes:. It would kind of make sense for magnets to oppose, otherwise they "could" pull magnets out of key head :unsure:

BTW found these possible solutions for key shutter locked, digging thru other post, either will require cutting key from scratch by a professional in the OP issue/case.



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Well searching on my phone found this 😁


Have to be a certified locksmith, etc., to buy it 😖 and know how to use it 🤔, but I bet an avid DIY'er can make one for emergency use for his scooter. With a dowel a few cheap "rare earth" magnets and super glue, etc 🙄🤔🤫
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Well, no word from O/P for a week :unsure:, hopefully is resolved.
IAC, I received my 2 Amazon/China key blanks today, very easy to set-up the magnets, best if you clamp key in a vise, etc. I used hemostat pliers and a toothpick to push into new key, just push until flush done, worked perfectly, will have it cut tomorrow and find a hiding spot on scooter. (y)

PS, work on a well-lit area and hold/clamp magnets firmly with pliers, they are very small and powerful magnets.

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Here's how I figured out the shutter magnet locations, without using the oem key as a reference, kind of a lost key situation, the pictures explain how I did it, believe me, this is a tedious/steady hand/good eyesight process, will definitely test your patience, magnets are very strong, small and easy to lose, there's no spares o_O, the best tools to place magnets is wooden dowel with two-sided foam tape or your fingers, you can do one magnet at the time then move to a diagram or fixture like in pics below. Believe me it took a while to get the magnets in place for the pics, as they pull hard and stick together very easily :((n)

BTW, I don't find this info to be a "Security Breach", there's how to videos on YouTube, etc., kind of like the super-secret ignition switch resistor :whistle:, most professional thieves would know a quicker/easier way to defeat this system, one thing for sure it could save you a lot of money if someone closes your shutter :censored:

IAC, Standard Disclaimer Here, try at your own risk, etc., "Flame Suit On"

Note: The colors were enhanced for clarity with paint program, the permanent markers I used were flat/dull.

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Well today was final "KEY" day :rolleyes: , finally got all the extra China/Amazon keys done for the Burgman, also cut a new OEM for the SW600, Locksmith I've used before cut all 3 for just $5 USD, worked perfect(y), grabbed a few key rings and gave him $10, Ace Hwd, charges $4 per key :eek: I did carry my vehicle titles to verify ownership, glad I did (y) I will hide a full working key in the scooters, just hope I remember where, later :rolleyes: Had a talk with locksmith about these magnetic keys, he said the code numbers on the locks will only get you the "Key cut diagram" from a website only available to Licensed locksmiths, etc. Not the magnet position for the shutter door. (n)

Maybe my ideas will help someone from getting robbed by stealership o_O

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I didn't like the key shutter either. It could be closed with anything that will go into the shutter keyhole or even a firm press and twist of the thumb. I figured the only one inconvenienced would be me. I made sure the shutter was fully open and put a few drops of Gorilla Glue in the works.
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