How do I assemble a topbox lock assembly - 2008 BMW F 800 GS

TO REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY (w/o Smart Key System)
(a) T urn the ignition switch lock cylinder assembly to the
ACC position.
(b) Insert a screwdriver into the hole of the steering column upper with switch bracket assembly. Pull the ignition switch lock cylinder assembly until its claw contacts the stopper of the steering column upper with switch bracket assembly.
(c ) Insert a screwdriver into the hole of the steering column
upper with switch bracket assembly. Tilt the screwdriver
to disengage the claw of the ignition switch lock cylinder assembly, and pull out the ignition switch lock cylinder assembly.



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You are going to need to replace the ignition switch

Disconnect power then open the door and remove the spring-hoop assembly that secures the door gasket. Peel off the part of the door gasket near the door lock and switch assembly. Remove the screws securing the door lock and switch assembly to the front panel then pull the door lock and switch assembly out. Transfer the wires to the new door lock and switch assembly then install into place. Put the door gasket back and secure it with the spring-hoop assembly. Click on the link below for the detailed procedure.

Replacing the Door Lock and Switch Assembly on Frigidaire Affinity and Gallery Front-Load Washing Machine

If you mean the ignition lock cylinder:

Ignition Lock Cylinder CAUTION
If the car is equipped with an air bag, do not service the steering column or dashboard components. Extreme danger of air bag deployment exists even with the battery removed! Serious injury could occur. REMOVAL & INSTALLATION Without Air Bag

1. Place the ignition switch in the RUN position.
2. Remove the lockplate, turn signal switch and buzzer switch.
3. Remove the screw and lock cylinder. NOTE: If the screw is dropped on removal, it could fall into the column, requiring complete disassembly to retrieve the screw. To install:
   
4. Rotate the cylinder clockwise to align cylinder key with the keyway in the housing.
5. Push the lock all the way in.
6. Install the screw. Tighten the screw to 14 inch lbs. (2 Nm) for adjustable columns and 25 inch lbs. (3 Nm) for standard columns.

With Air Bag CAUTION
Before proceeding, refer to Section 6 for information on disabling and enabling the SIR (air bag) system; otherwise, serious injury could occur.

1. Turn the steering wheel so the vehicles wheels are pointed straight ahead.
2. Place the ignition switch into the LOCK position to prevent undercentering of the coil assembly.
3. Disable the SIR system. Disconnect the negative battery cable.
4. Remove the coil assembly retaining ring, then disconnect the inflatable restraint coil assembly. Let the switch hang freely if removal is not needed. To remove the coil assembly proceed.
5. Remove the wave washer, then the shaft retaining lock ring with tool J-23653-SIR to push down on the shaft lock. Dispose of the ring, it is not reusable. Fig. 1: Special tool J-23653-SIR or equivalent is required for pushing down the shaft lock to remove the shaft ring
   
6. Remove the shaft lock, then disconnect the canceling cam assembly.
7. Remove the upper bearing spring, race seat and race.
8. Position the turn signal to the right turn (up) position.
9. Remove the multi-function lever and hazard knob assembly. Unfasten the round washer head screw and signal switch arm, along with the turn signal switch screws.
10. Remove the turn signal switch assembly by unfastening the connector from the bulkhead connector. Gently pull on the harness through the column and disconnect.
11. Make sure the coil assembly does not become uncentered, this could happen if the centering spring is pushed down letting the hub rotate while the coil is removed from the steering column.
12. Remove the inflatable restraint coil assembly with the wiring harness from the column assembly.
13. Remove the wire protector, then attach a length of mechanics wire to the coil terminal connector to aid in reassembly. Then gently pull the wire through the column.
14. Remove the key from the steering column lock cylinder set, then remove the buzzer switch assembly.
15. Reinsert the key into the lock cylinder, turn it to the LOCK position.
16. Remove the lock retaining screw, then the cylinder. To install: NOTE: Make sure all fasteners are securely seated before applying the necessary torque. If you fail to do so, component damage or malfunctioning of the steering column may occur.
    
17. Install the lock cylinder assembly, insert the retaining screw, then tighten to 22 inch lbs. (2.5 Nm).
18. Insert the key into the lock cylinder. Install the buzzer switch assembly. Turn the key to the LOCK position.
19. Install the turn signal switch assembly wiring harness through the column, let the switch hang freely. Connect the wiring to the bulkhead.
20. Insert the coil assembly wiring harness through the column letting the coil hang freely. Attach the turn signal assembly with the binding head screws. Tighten the screws to 30 inch lbs. (3 Nm).
21. Attach the signal switch arm with the round washer head screw, tighten the screw to 20 inch lbs. (2 Nm).
22. Install the hazard knob assembly and the multi-function lever.
23. Install the inner race, upper bearing race seat and spring. Attach the turn signal cancelling cam assembly, apply grease for lubrication.
24. Replace the shaft lock and install a new shaft lock retaining ring. Use tool J-23653–SIR or equivalent to push down on the shaft lock. The ring must be firmly seated in the groove on the shaft. NOTE: Set the steering shaft so that the block tooth on the race and upper shaft is at the 12 o'clock position. The wheel on the car should be straight ahead. Set the ignition switch to the LOCK position, as this will ensure no damage to the coil assembly.
    
25. Install the wave washer, then attach the coil assembly, make sure it is centered correctly. Fig. 2: Centering the coil assembly is important in assembling the column assembly
    
    
26. Attach the coil assembly retaining ring, the ring must be firmly seated in the groove on the shaft.
27. Gently pull the lower coil assembly, turn signal, and pivot (pulse) wires to remove any kinks that may be inside the steering column assembly. If you fail to do this you can damage the wiring.
28. Complete assembling the steering column assembly.
29. Attach the negative battery cable.
30. Check the functions of the turn signal, make sure it cancels when turned on and the steering wheel is turned.
31. Enable the SIR system.

You have to remove the steering wheel with a puller,and the lock plate ,with a lock plate remover tool,and the cancel for the turn signals,and then the turn signal switch,then you remove a screw on the right side about 2 o clock position,and the lock and key will slide out.

Automatic Locking Hub

1. Shift transfer lever to the ``2H'' position, then move vehicle forward and rearward approximately three feet.
2. Raise and support vehicle, then remove wheel and tire assemblies.
3. Disconnect brake hose from caliper.
4. Remove caliper locking bolt.
5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly
6. Remove brake pad support bracket.
7. Remove hub cap retaining bolts, then the hub cap, Fig. 15.
8. Remove housing assembly, snap ring and shims.
9. Remove drive clutch assembly, inner cam and lock washer.
10. Using tool J-36827 or equivalent, remove hub nut.
11. Remove hub and disc assembly.Manual Locking Hub
    
    
    1. Shift transfer lever to the ``2H'' position and set free wheeling hub into Free position.
    2. Raise and support vehicle, then remove wheel and tire assemblies.
    3. Disconnect brake hose from caliper.
    4. Remove caliper locking bolt.
    5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly
    6. Remove brake pad support bracket.
    7. Remove housing assembly retaining bolts then the housing assembly Fig. 16.
    8. Remove snap ring and shims.
    9. Remove body assembly and lock washer.
    10. Using tool J-36827 or equivalent, remove hub nut.
    11. Remove hub and disc assembly

When carrying a live inflator module, make sure that the bag and trim cover are pointed away from you. Never carry the inflator module by the wires or connector on the underside of the module. In case of accidental deployment, the bag will then deploy with minimal chance of injury.
When placing a live inflator module on a bench or other surface, always face the bag and trim cover up, away from the surface.

1. Disconnect the negative battery cable and disable the SIR system.
   
2. Remove the upper and lower shroud, air bag module and the steering column.
   

Exploded view of the removal of the SIR coil assembly

1. Remove the retaining ring, SIR coil assembly, wave washer.
   
2. Remove the shaft lock retaining ring using tool J 23653-SIR or its equivalent to push down the shaft lock shield assembly. Discard the ring.
   
3. Remove the shaft lock shield and turn signal cancel cam assembly.
   
4. Remove the park lock cable assembly from the lock module assembly.
   
5. Remove the key alarm switch, if equipped by gently prying the alarm switch retaining clip with a small pry tool. Rotate the alarm switch 1/4 in. turn and remove.
   
6. Remove the two tapping screws and the ignition key and alarm assembly. Let the switch hang freely.
   

CAUTION The lock assembly is under slight spring tension. Hold the lock bolt in place while removing the lock module assembly.

1. Remove the three pan head tapping screws and the lock module assembly.
   
2. Remove the backing plate from the module.
   

Mark the two sector gears at the OFF-LOCK position to ensure proper reassembly

1. Remove the sector gears.
   
2. Remove the positioning tab on the end of the lock cylinder using an 1/8 in. burring tool. Remove all burrs from the lock module and cylinder assembly.
   
3. Push on the locking tab of the lock cylinder from inside the lock module assembly and remove the lock cylinder.
   

To install:

1. Align the marks on the sector gears and install the gears and the backing plate to the lock module assembly.
   
2. Install the lock cylinder set and ensure that the lock module assembly is in the OFF-LOCK position.
   
3. Install the key in the lock cylinder and ensure that it is in the OFF-LOCK position.
   
4. Line up the locking tab with the slots in the lock module assembly and push the cylinder into position.
   
5. Rotate the lock cylinder to the ACC position. The alignment arrows on the sector gears should be pointing towards each other.
   
6. Rotate the lock cylinder to the LOCK position. Push the lock bolt in until it is flush and align the lock module assembly with the head assembly and install the lock module assembly.
   
7. Install the three pan head screws and tighten to 53 inch. lbs. (6 Nm).
   
8. Install the ignition and key alarm switch assembly and the fasteners. Tighten the fasteners to 12 inch. lbs. (1 Nm).
   
9. Install the key alarm switch. Make sure the retaining clip is parallel to the lock cylinder. Rotate the alarm switch 1/4 in. turn until locked in place.
   
10. Lubricate the lower brass surface of the turn signal cancel cam assembly with synthetic grease and install the assembly.
    
11. Align the inner block tooth of the lock plate to block tooth of race and upper shaft assembly and install the assembly.
    
12. Install a new shaft lock ring using tool J 23653-SIR and ensure the ring is firmly seated in the groove on the shaft.
    
13. Install the center race and upper shaft assembly.
    
14. Place the ignition switch to the lock assembly and ensure the coil is centered.
    
15. Install the wave washer and the SIR coil assembly.
    
16. Install the retaining ring and route the coil wire along the steering column.
    
17. Install the wire harness straps to the steering column harness.
    
18. Install the park lock cable assembly with the transmission in Park and the ignition switch in the OFF-LOCK position.
    
19. Install the upper and lower covers, lock cylinder set and tilt lever (if equipped).
    
20. Install the steering column and enable the SIR system. Connect the negative battery cable.
    

Exploded view of the sector gear timing position (OFF-LOCK)



Remove all burrs from the lock module and cylinder assembly

There is an auxiliary switch in the door lock and switch assembly that is activated at the end of the wash cycle to advance to the spin cycle. When the machine works except advancing to the spin cycle, it signifies that this auxiliary switch cannot be activated and the door lock and switch assembly is faulty. Replaced the door lock and switch assembly (part #131763202) to fix the washer.

Disconnect power to the machine. Open the washer door then look for the retaining hoop securing the door seal around the lip of the door opening. Stretch the retainer spring of the door seal retaining hoop then remove it.

Carefully peel off part of the door seal from the lip of the door opening near the door lock and switch assembly. Remove enough of the door seal to gain access to the door lock and switch assembly.

Remove the screws securing the door lock and switch assembly to the front panel. Once the screws are removed, lift the door lock and switch assembly then pull it away from the front panel.

Take the door lock and switch assembly out of the machine. Disconnect the wires from its terminals then connect it to the new door lock and switch assembly.

Put the new door lock and switch assembly back into position in the front panel and secure it with the securing screws.

Properly put the eased part of the door seal back over the lip of the door opening then secure it with the retaining hoop.

remove the steering wheel , need a puller and locking ring tool, disconnect batt, turn the key to tho on position, and remove bolt that holds the tumbler in,

i had the same prob..and the cure was to change the bushes on the motor.its been fine since