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Thread: Broken key in ignition -2004 Mojito 150 custom

  1. #1
    apriliaforum newb
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    Broken key in ignition -2004 Mojito 150 custom

    My key broke inside the ignition of my 2004 Mojito Custom 150.
    I tried to pull the broke piece out of the ignition with pliers but was unable to.

    There is a shear rivet bolt the hold the ignition to the frame and on the bottom there is the electronic part held on with Phillip head screws.

    If I remove the bottom portion of the ignition, can I push the broken key through the tumblers?

    If not, I guess I will grind off the shear rivet and attempt to remove the broken key. If I don't succeed, I'll buy a new ignition switch.

    Any thoughts?

    Thanks,

    pete

  2. #2
    apriliaforum expert
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    A lock smith should be able to get it out with dental type picks and it will be cheaper than buying a new ignition switch and less work than installing it.

    You should be able to get it out with a set of these and a little finesse (one on each side):
    https://www.harborfreight.com/6-piec...set-93514.html

  3. #3
    apriliaforum Member Pinkscoot's Avatar
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    Have you tried a magnet?
    Italian scoots owned: 2003 Scarabeo 150, 1998 Italjet Velocifero, 2009 Vespa GTS 250, 2012 Vespa S50, 2007 BV 250, 2014 Aprilia SR50 Purejet, 1977 150 Sprint Veloce (future project) and Vespa ET2 (future project)

  4. #4
    apriliaforum expert
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    take the ignition off and remove the electrical part of the ignition
    you can push out the key from the other side with a pick or a peace of wire

  5. #5
    apriliaforum expert
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    Quote Originally Posted by Pinkscoot View Post
    Have you tried a magnet?
    Ignition keys are usually not made of metals that would be attracted by a magnet as also would be the case with most locks with pins as a steel key would wear the locks pins out very quickly.

    Personally I use the picks or just thin out the nose of a pare of needle nose pliers with a grinder (don't overheat and weaken the steel) so it will slide in and grab broken keys. So far in over 50 years I have not had to disassemble a lock to get a broken key out. Just takes a little thought and finesse and I'm a 250 lb gorilla so a bit more prone to having a lack of finesse.

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