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[coopedup1980]

Model:Sprite
Year:1993
Description of problem (please be as in depth as possible): Boot will not lock with key. Serial number on barrel is the same as the key


The lock hasn't worked since I got the mini...boot had been changed over to a fibre glass one. So I was just hoping that maybe the lock has been returned upside down. No luck.

Taken the boot handle off and am now trying to dismantle...hope of fixiing/correcting. But how?

I've WD40'd it up but can't figure it out.

Don't really fancy replacing....yet another lock.

Cheers,
Neil

[coopedup1980]

So I have sorted it...all it was down to a badly corroded/crudded up mechanism.

1. Remove boot lock. 4 screws holding on the cover. 2 nuts holding on the handle.
2. The handle has two parts, the actual handle and an open barrel that the handle "locks" in to.
3. Remove split washer. To remove I started of at the split using a large screwdriver (a lot more leverage than a skinny one like I started with) and made my way round. I used a lot of force...I'd say it'd take a lot to break this but do be careful (disclaimer...you break it, your problem)
4. Remove x3 wavy washers.
5. Knock out retaining pin (about half way down lock barrel). This may be covered in crud like mine was and not visible. A good wash with WD40 now would be good. With this out and key in you should be able to remove the lock barrel.

This is where I found the problem. Lots of crud was stopping the locking pins to slide down preventing key turn. LOTS of WD40 and very good clean until pins moved up and down freely when putting the key in/out. When removing the barrel from lock be sure to note the way that the lock stud goes (has a groove that should face towards the key when in place, its this that actually locks the handle in place).

5. Replace the lock barrel into the handle. Be sure to check that key and handle work efficiently (I used grease to be sure) and the locking stud actually now pops out to one side.
6. Feed the handle back through the open barrel and lock in place with key. Stops it moving.
7. Replace x3 wavy washers.
8. Replace the split washer. I found it easier to start the opposite side to the split and then nudge it down either side again using a large screw driver. Again a lot of pressure used. but you break it, your problem.
9. Re-attach to boot. x2 nuts. x4 retaining screws.

Job done.