Most locksmiths do not stock the proper key blank and typically their references for Kawasaki Ninjas are wrong on what blank to use. In my career I have came across both a 250 owner and 636 owner that had this problem. And the locksmith they were using was unable to figure the problem out. I have. :-)

The Symptoms: Duplicate key works everything except ignition

The Cause: The key blank used on the duplicate is not machined to go deep enough into the ignition. Everything except the ignition works because those locks only use a few cuts off the tip of the key.

The Solution: Dremel tool the keyway to extend further down the key, the images should explain everything

NOTE: Do not modify the cuts or obviously the key won't work!

I have photoshop but mspaint felt more OG.

This was written by a Microsoft Certified Professional who also has a Locksmith License. Lol. It goes abut TWOOO FIDDY!


If you are not a member scroll down I replied to the thread with externally linked images so you don't have to register.

 

helpful lol

 

Here are the images externally linked for those who aren't members like other locksmiths finding this thread on google when searching "Why can't I duplicate Kawasaki Ninja Keys?".

Though I suggest you do register even if you don't stunt, the videos and pics are great!

 

I don't recommend the cut off wheel, use a cylinder sanding pad it will look much cleaner and just follow the key way groove with it up to the bow. Both those key blanks he mentioned are the WRONG blank and he is saying how he would modify them to work. Well MAYBE X103 is right but the milling on SOME blanks doesn't extend far enough, I'm not sure I don't have any reference material on bikes. But anyways, enough information has been posted that if you weren't able to get the duplicate to work that you can now modify it.

From wes at Ninja250.org

 

I also used a licensed locksmith to change the lock of my Kawasaki.