Kwikset Rekeying Manual

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Contents

How a Lock Works . . . . . . . . . . . . . . . . . . . . . 2

Tools to Rekey. . . . . . . . . . . . . . . . . . . . . . . . . 3

How to Gauge a Kwikset Key . . . . . . . . . . . . . 4

Key Duplication . . . . . . . . . . . . . . . . . . . . . . . . 5

Masterkeying . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Keying Master Cylinders . . . . . . . . . . . . . . . . . 7

Rekeying Knobs . . . . . . . . . . . . . . . . . . . . . . . 8

Rekeying Laurel Eggknob . . . . . . . . . . . . . . . 12

Rekeying Knobs . . . . . . . . . . . . . . . . . . . . . . 14

with a control key

Rekeying Knobs . . . . . . . . . . . . . . . . . . . . . . 16

with a standard operating key but without a control key

Rekeying Knobs . . . . . . . . . . . . . . . . . . . . . . 19

what to do if top pins and springs drop out during rekeying

Rekeying Levers . . . . . . . . . . . . . . . . . . . . . . 20

Rekeying Levers . . . . . . . . . . . . . . . . . . . . . . 21

for Commercial Series levers

Rekeying Handlesets . . . . . . . . . . . . . . . . . . 22

Rekeying Deadbolts . . . . . . . . . . . . . . . . . . . 24

Rekeying 780 Deadbolt. . . . . . . . . . . . . . . . . 27

with a control key

Rekeying 780 & 980 Deadbolt . . . . . . . . . . . 30

without a control key

Rekeying 780 & 980 Deadbolt . . . . . . . . . . . 32

without a key or control key

Rekeying 980 Deadbolt. . . . . . . . . . . . . . . . . 33

what to do if top pins and springs drop out during rekeying

The Society Brass Collection

Rekeying Knobs & Levers. . . . . . . . . . . . . . . 35

Rekeying Low Profile Deadbolt . . . . . . . . . . . 37

with existing key

Rekeying Low Profile Deadbolt . . . . . . . . . . . 38

without existing key or if springs have fallen out

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

bitting . . . . . . . . . . . . key cuts that form the combination.

blade . . . . . . . . . . . . the portion of a key and/or milling.

bow . . . . . . . . . . . . . the portion of the key which serves as a

grip or handle.

bow stop . . . . . . . . . a type of stop located near the key bow.

chamber . . . . . . . . . any cavity in a cylinder plug and/or shell

which houses the tumblers.

combinate . . . . . . . . the pinning of the actual cuts on the key.

Control Key . . . . . . . available for most TITAN products, allows

removal of cylinder without dismantling

lock.

cylinder assembly . . holds the plug, pins, springs and cover.

cylinder guard . . . . . heavy duty cover for cylinder housing.

cylinder housing . . . contains the cylinder assembly.

cylinder removing tool for removing and replacing plug retainer.

gauge . . . . . . . . . . . . the act of determining the bitting of the key

handing . . . . . . . . . . the orientation of the knob, handle, or lever

with respect to a left or right sided door

(see illustration on page 20).

lever catch . . . . . . . . spring mounted piece, holds lever in place

locking bar . . . . . . . . prevents removal of UltraMax cylinder with-

out Control Key use or retainer removal.

mechanism module . keyed entry lockset assembly for new

keyed handlesets.

PK holes . . . . . . . . . Protecto Key, allows new homes to be

keyed to a builder’s key, and once home-

owner uses their key, builder is locked out.

plug . . . . . . . . . . . . . holds the bottom pins and keyway.

plug follower . . . . . . used to push the plug out and hold top

pins and springs in place while rekeying

plug.

plug retainer . . . . . . “C” style clip, holds plug in cylinder hous-

ing.

shear line . . . . . . . . . when the bottom pins are correct, a shear

line is created when the proper key is

inserted allowing rotation of plug.

shield . . . . . . . . . . . . for additional security on exterior knobs.

sleeve . . . . . . . . . . . assembly holding cylinder and lever.

spindle . . . . . . . . . . . two types; a round and half-round spindle.

spring cover . . . . . . . snap on cover to hold pin springs in place.

spring housing . . . . . holds return spring for lever or knob in

place.

tailpiece . . . . . . . . . . spindle like extension for deadbolts.

thumbpiece pin . . . . holds the handlesets thumbpiece in place.

Glossary of Terms

How a Lock Works

5-Pin System

Kwikset locks operate by matching the cuts on the keys with the bottom

pin tumblers inside the cylinder plug.

There are two sets of five pins in each lock, top and bottom, and a set of

springs. The top pins are all the same size and are flat on both ends. You

do not, at least right now, want to deal with top pins or springs.

You only want to deal with bottom pins, which are of different lengths (in

.023” increments) and are tapered on both ends.

For the lock to work, the cuts of the key must enable all five bottom pins

to be flush with the cylinder plug. This is called the shear line.

In the top photo, there is no shear line because some bottom pins are out

of place. That key won’t operate this lock.

Put in the correct key (middle photo) and all the pins line up to form the

shear line and the key will operate the lock (bottom).

When you rekey a lock, you simply replace the bottom pins according to

the cut combination of the key you want to use. And you can do all this

with a few very simple tools.

6-Pin System

UltraMax Security locks operate by matching the cuts on the keys with

the bottom pin tumblers inside the cylinder plug.

There are two sets of six pins in each lock, top and bottom, and a set of

springs. The top pins are all the same size and are flat on both ends.

You only want to deal with bottom pins, which are of different lengths (in

.023” increments) and are chamfered on both ends.

For the lock to work, the cuts of the key must enable all six bottom pins

to be flush with the cylinder plug. This area is called the shear line.

In the top photo (Figure 1), with no key or the incorrect key, some bottom

pins and some top pins block the shear line. That key won’t operate this

lock.

In the middle photo (Figure 2), with the correct key, all the pins line up at

the shear line. The key will turn and operate the lock (Figure 3).

When you rekey a lock, you simply replace the bottom pins according to

the “bitting” (cut combination) of the key you want to use.

Cut-Away View

of Lock Cylinder

Figure 1

Springs

Shear Line

Bottom Pins

Spring Cover

Top Pins

Plug

Springs

Shear Line

Bottom Pins

Spring Cover

Top Pins

Plug

Cut-Away View

of Lock Cylinder

Figure 2

Figure 3

Tools to Rekey

Inside a Kwikset/Society Brass Collection Rekeying Kit

are the different bottom pin sizes you need to rekey

a lock, a Key Gauge for reading the cuts on a key, a

Cylinder Removing Tool (affectionately known as a “pick-

le fork”), and a plug follower. This is a very simple device

which keeps lock parts from scattering across the room

when you remove the plug (which houses the pins, and

into which the key fits) from the cylinder.

There are also extra top pins, springs and other parts in the

kit, but you do not need to be concerned with those now.

(Shown: Keying Kit No. 272 contents)

Cylinder Removing Tool

Plug Follower

Key Gauge

Control Key for UltraMax knobs

locks cut from key blank #87615

How to Gauge a Kwikset Key

Before you can rekey a lock, you have to know what pins to use. For

obvious security reasons, Kwikset doesn’t print key-cut combinations

on the packaging. We use this Key Gauge to find the key-cut combi-

nations. Before disassembling the lock, measure the cuts and write

down the numbers.

Hold the NEW key (the one with which you want this lock to be keyed

alike) and slide it into the gauge. ALWAYS gauge a key from the bow

(the bow being the part you hold in your fingers) end out. To measure,

position the flat portion of the first cut even with the “0” position of the

gauge, slide the key toward the narrowing end of the gauge until the key

stops at the correct “step”. This will always be between two numbers

and the cut number is the one to the RIGHT of the key. Here it is a 3.

Position the next cut and move the key down the gauge until it

stops. The second cut of this key is a 2. You can slide the gauge or

the key, the result is the same. The first cut comes after the shoulder

next to the bow.

Do the same for the third cut which is a 4. Remember, always read

the number to the right of the key. Also, remember to read the cuts from

the bow of the key out (the bow being the part you hold with your fingers).

7 6 5 432 10

432

Positions

1 2 3 4 5

Combination

32462

It’s also a good idea to double-check that you are reading the correct

cut each time. In this case, cut number four is a 6.

Finally, the last cut: a 2. So we have a key with a cut combination of

3-2-4-6-2 (if this is a UltraMax Security key, there will be six cuts

to gauge). Of course, you’ve written that down as you went along.

When the time comes, you’ll know exactly which pins to select.

Locate the special “control key” which is cut specifically for the

combination of your lock, but with a notch on the bottom of the key

blade.

NOTE: If not available, cut a blank “control key” to match

existing key.

Key Duplication

Instructions for duplicating cuts from a five pin Kwikset key to a six pin Kwikset or Society Brass key. This permits

Kwikset and Society Brass to be keyed alike.

Measure the Kwikset key and write down the key cut combination.

These will be the depths required for positions 2 through 6 on the 6

pin key. Save the results for re-pinning the cylinder.

The key duplicator must be of the type that stops against the keys top

shoulder. Insert both the Kwikset key and the key blank. Positions 2

through 6 are then cut. Position 1 will be bypassed.

2Kwikset key Key blank

Depth keys are used to duplicate the remaining cut in position 1 of

the key. Select depth at random from the 3 keys supplied. Only posi-

tion 1 has been cut, to prevent contact with any other cut. The cylin-

der will be pinned to this key cut.

Insert both the depth key and the previously cut key in the key duplica-

tor. Now position 1 of the key is cut to match the depth key. Additional

keys may now be duplicated in the usual manner.

4Depth key Kwikset key

Rekeying Low Profile

Deadbolt

without existing key

or if springs have fallen out

Step-by-step instructions for:

1 2

Slide spring cap back with awl or small slotted screwdriver.

Remove springs and top pins, then remove E-clip and re-key plug.

After replacing pins and springs, slowly slide cap back on.

After re-pinning, replace plug and apply E-clip and torque blade.

If you slide this slowly, your springs will not fly.

Load top pins (.180) and springs from top, slide spring cover back

on, pressing the springs down, one at a time, with a small slotted

screwdriver, as you slide cap over them.

Keying Master Cylinders

Model 740 cylinder is illustrated. Other cylinders are keyed in same manner.

Remove plug clip

Push plug clip (1) off with screwdriver or cylinder removing tool,

using a side-to-side motion.

Remove plug

Insert key and turn plug 1/4 turn clockwise. Push plug out of cylinder

with plug following tool (2) and leave in cylinder. the plug following

tool will keep the top tumbler pins and springs in place.

Drop pins out of plug.

Key measurement

Measure cuts of key or keys as illustrated, and write down key cut

combinations.

432

FOR ALL KWIKSET

USING .02

For random keying

Random keying uses only one key. For multiple keys, refer to page

6 (Masterkeying). Insert key into plug. Drop bottom pins into proper

holes with pin numbers that match measured depths. Tops of pins

should be flush with outside diameter of plug.

Protecto Keying

Larger kits are capable of Protecto Keying. This is used for new con-

struction and similar to Masterkeying. Use 3 balls in place of a #2

master Pin. Builders key will have a cut two increments deeper than

homeowners random key in selected chamber.

PIN SPRINGS

TOP PIN

SHEARLINE

PK BALLS

BOTTOM PIN

BUILDERS KEY CUT

Rekeying Knobs

Tab

Cylinder

Removing Tool

Round Spindle

Stem

Cylinder

Removing Tool

Stem

Spring

Housing

Round Spindle

Cylinder Removing Tool

Be sure to remove key from cylinder before starting. In order to

remove the round spindle, align the tab so it is perpendicular to the

bottom of the half-round, as shown at right.

Insert the pointed end of the Cylinder Removing Tool into the end of

the spindle and turn until the tab is lined up with the stems.

Insert small end of the Cylinder removing Tool at an angle against

stem, sliding under edge of spring housing. Push in firmly on retainer.

Hold the lock with the spindle down and it will fall out. If not, keep pres-

sing with the tool and use your thumb to slide the round spindle out.

If the round spindle rotates, you will need to repeat steps 1

- 4.

Forked End

of Cylinder

Removing Tool

Half

Round

Spindle

Spring Housing

Half

Round

Spindle

To remove the cylinder, place the forked end of the tool down the

half-round spindle through spring housing. You’ll see a hole there,

and you have to fit the forked end of the Cylinder Removing Tool

under the top of that hole and pry it open.

Once you have “opened” the spring housing, slide the tool all the

way in until it stops. Be firm, but not forceful. Keep the Cylinder

Removing Tool perpendicular to the half-round spindle at all times.

Step-by-step instructions for:

Half Round

Spindle

Cylinder Removing Tool

With the Cylinder Removing Tool all the way in, put your other hand

over the outside of the knob, covering the cylinder and plug.

The cylinder will come right out in your hand. For most, this is the

most difficult part of rekeying. It takes practice to get the tool in

under the spring housing, and getting just the right motion and pres-

sure to pop the cylinder loose.

Plug Follower

Plug

13 14

Slide the EXISTING key for this lock into the keyway and turn the key

about 45° to the right or left. Keep key at this angle for next step.

Be sure not to let key cylinder slide out.

Still holding the plug firmly in the cylinder, use the flat end of the

plug follower (the notched end is for a different kind of cylinder) to

PUSH the plug out gently and evenly from the rear. Push it steadily,

do not pull the plug.

Keep pushing until the tool sticks out at least an inch. Leave it in

place until you reassemble. Carefully remove the plug, holding

it by the key and don’t turn it.

Now you can see the bottom pins in the plug. Turn it over to dump

them out and discard them. It’s not worth the time and possible sort-

ing errors to restock them.

Cylinder

Removing

Tool Plug Retainer

Plug Retainer

Cylinder Removing Tool

Use the forked end of the Cylinder Removing Tool to disengage plug

retainer.

Then use the small end to free it completely. Use care not to deform

plug retainer.

Plug Retainer

21 22

Put the plug retainer back in from the side of the spring cylinder as

shown and use the Cylinder Removing Tool to snap it back into place.

Be sure the inside edges of the retainer line up with grooves in the plug.

Insert the key and turn it back to the vertical position, in line with the

spring cover on top of the cylinder.

Spring Cover

Plug Follower

Plug

Spring Cover

Install pins one by one, from the front (bow) to the back (tip) and be

sure they are all flush with the top surface of the plug. A pin which

is too long will prevent plug insertion with the key installed. A pin

which is too short will cause the lock to malfunction.

Now all you have to do is reassemble the plug into the cylinder hous-

ing in exactly the reverse order. Start by placing the end of the plug

against the end of the plug follower. Again, turn the key so it is about

45° to the right or left of the spring cover. Then slowly and smoothly

PUSH the plug follower back into the cylinder with the plug.

When it’s all the way in the cylinder, turn the key so it is in line with

the spring cover on top of the cylinder. You’re done with the plug fol-

lower, but hold the plug and cylinder firmly together.

This is important. Hold the plug all the way into the cylinder with your

thumb. Making sure the key is still in line with the pin cover, pull out

the key. Keep pressure on the plug until the key is out.

15 16

Checking the key bitting (combination) you gauged earlier, you’ll

select the pins which match those cuts from the appropriate com-

partments in the Rekeying Kit. Example: 3-2-4-6-2. A No. 3 bottom

pin to a No. 3 key cut depth, a No. 2 to a No. 2, etc.

Put the new key into the plug and, working from the bow (front) end

of the plug, drop the first pin into its chamber – here a No. 3. Some

people find using their fingers easier, others prefer tweezers. Either

way, it takes some patience to deal with these tiny pins.

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摘要：

1ContentsHowaLockWorks.....................2ToolstoRekey.........................3HowtoGaugeaKwiksetKey.............4KeyDuplication........................5Masterkeying..........................6KeyingMasterCylinders.................7RekeyingKnobs.......................8RekeyingLaurelEggknob...........

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