I have just bought a 2004 XT660R.

The bike was stolen/recovered and the ignition barrel is faulty. The keys will pull out when the switch is on and sometimes it's very stiff and wont turn.

I basically need a new ignition barrel. However !! READ ON !!

The previous owner aready had a bike shop replace the ignition barrel with this one as the original was destoryed during the theft. But 'apparently' they didn't change anything else.

Now, from reading this forum, I read that you have to change more than the barrel due to the immobiliser. Some saying it needs a new ECU and has to be coded. I'm trying to work out what they have done. Some kind of bodge or workaround ?? Because the owner says they changed nothing but the barrel with a second hand one.

Under normal circumstance, if you wanted to change the ignition barrel, what else would you have to change ??

I wonder since you have the original key, would it be possible to find a locksmith to make a barrel chamber, with the necessary pins and tumblers, from the profile of your key? That would mechanically repair things.

The bike does need its matching chipped key fob, immobiliser key fob pick up at the barrel and ECU to electronically complete the ignition, all of which you still have, I guess.

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I have a lot of growing up to do. I realized that the other day inside my fort.

I read the post as the current ignition barrel was a replacement after the theft, and assumed rightly or wrongly that it came with keys.

Happy to be corrected though.

You could be correct. I guessed that since the bike was stolen and then barrelled the original owner was left with the original keys and the bike shop fitted a used (bodged) barrel chamber that doesn't match the original key. I wonder if his bike starts and it's just a crap lock fit.

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I have a lot of growing up to do. I realized that the other day inside my fort.

Sorry for the late reply here. I have been overseas.

Yes. The bike starts and runs fine with the replaced barrel. It doesn't need the old keys to be anywhere near the bike.

I have the old keys for the fuel cap and the seat lock.


The replacement barrel and keys are genuine Yamaha XT660. Bought from Ebay in Italy !!

The barrel and the key are a match. The barrel won't turn without these keys. The original keys do not work in the ignition barrel.


As far as I am aware, the ECU is the original and the barrel is off ebay !

Should this work ?????

Id just leave what isnt totally broke incase you made it worse and buy good lock and alarm with money as the little b**tards by us are taking them all the time and if they got an eye on it they only gonna break it again to steal it so don't bother not like it stopped them last time can't wait for the law to change in UK as the police can't even chase them and then maybe they will be able to knock the b**stards off and cause them some damage like they do to the people's bikes they have stole I am from by you so if you get up the tap pub on a Wednesday have a look at it and maybe we could go for a blast up to peak District one weekend as don't know anyone else with a 660 R from wirral to do a bit of off-roading with hope you up for some of the bumpy stuff!