Help. I brought the bike to NI and took the panniers off to empty them. When I went to open the lock the key has broken in the barrel so I can't open the case and can't refit the cases.
Can anyone help with the best solution?

It is not an uncommon fault. Quite a few barrel and key sets were changed under warranty due to stiff locks and broken keys. They revised the key slightly to help fix the problem, but all they did in reality was shorten it!

You will need to remove the barrel from the pannier to extract the broken bit of key. Quite how you're going to do that with the pannier locked shut I don't know? Can't really help anymore than that as my Yamaha panniers were disposed of many years ago (before they broke)!

Replacement locks and keys were available from dealers. Whether they still are is another matter.

Have you read this thread? Also this.

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Thanks for the reply.
Yeah I'd had a look at them earlier but being an 09 bike and 3rd owner I figured any yamaha dealer won't be interested.
Aye I'm a bit stuck, both panniers off bike, one open, one locked shut and heading back to Scotland on Tuesday. I think I'll have to try a local locksmiths and see what they say

I think that you can get in from the bottom. Just remove the screws in the corners and i thinkt you cake the bottom of and from there remove the inner panel the hides the mechanism

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2011 Yamaha XT660Z ABS T�n�r�.

• Puig +8cm dark screen, Garmin Zumo 220, Scottoiler eSystem v2
• Barkbusters Storm with external weights, Noname 30mm bar risers & EzMoto alu. levers
• Kev's O2 Controller, Mccoi stepless controller with Hein Gericke heated grips
• TT +4cm seat, Pivot Pegs, Altech stainless sprocket cover

Thanks for that but thankfully I managed to get the broken bit out without any damage and got two new keys cut today.
I do like the oem panniers and the rack but it has concerned me a little