I learned something about keys...
Just today, I went to Ace Westlake Hardware store to have them to make copies of motorcycle keys. The former Owner of Suzuki Volusia told me that he had another key (one of two original keys) somewhere in his house and can't find it. I have only one key and don't want to lose it or else I have to hack the ignition. So I was wanting two extra copy of keys so If I lose one, I would have backup. The hardware guy pulled out the case for Suzuki motorcycle keys only, He and I were comparing which one of key that look similar (he picked short keys but have similar shape). So he made two copies that I request for. I paid for it and went home. Excitedly, I put key in ignition and it won't turn the ignition. But it can unlock gas cap, helmet lock, and side storage lock with no issue. I began to wonder why it won't turn ignition. I decide to compare copied key against original key. It look fine to me and I decide to use Dremel tool with thin disk grinder to grind small part of notch that I think it may not be deep. I grind just about 1/50th inch ( just wee bit). So it look very much the same as original, I tried again and it still doesn't turn. I wiggle, jiggled and even use vise grip and carefully wiggle with a little force, none avail!!!
make me wonder WHY!!! So I decide to take a real good look at keys against original. After few minute inspection, THERE!!! It's the middle side groove on copied key was wider than original...
So I decide to head back to Ace Westlake and see if they have longer key just like mine with narrow side groove. The guy and I took another look in the key box. I saw one chubby hole of long blank key and decide to take it out and compare with original shape and size. Indeed it is a perfect match. He hesitate that It's for car. I told him that my motorcycle is big and it have push spring to lock handle bar as well as ignition. Copied key won't push in with spring feel. So I told him just go ahead and make copy and I'm just betting my money on that key. He Ok'd and went ahead and made one copy. I took it home and tested on my Volusia, Bingo!! Puurrrrffeectt and it turns ignition and spring pushed in and turned to lock handlebar. So I went back to Ace Hardware and told guy it's perfect!! so make me 2nd copy. So he made 2nd and I'm happy and felt much better to have spares!!
What's interesting about key side groove, Even though short blank key look very much the same as original but have wider middle groove if you look carefully. It wouldn't turn the ignition even if it's a exact copy. Other key that have narrow middle groove which is a perfect match can turn the ignition. I realized that it's a security feature that Susuki have that prevent thief from turning the ignition if he use wide side grooved key. I could guess that inside of ignition keyhole have side spring that prevent ignition from turning if side groove is wide.
So now that I have 3 set of keys for my motorcycle.
Catty