Replacing door locks

[Crow]

Have no keys for Adv North Star 2024 bought lock kit but instructions are for putting new ones in by using keys .
How do you remove the old ones?

 

[TMIG68]

It can be a little bit complicated and if you're not careful you'll break some plastic clips that are a nightmare from what I understand. Sounds like better off taking it to the dealer. Let them do it.

 

[JohnnyG]

I uploaded the manuel to ChatGPT and then asked. Here is what it said:

These doors use a removable lock cylinder retained by a spring clip inside the door. Losing the key does not prevent replacement.

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What You’ll Need​

Parts​

• Replacement door lock cylinder(s)
  
  • OEM from Polaris
  • Or aftermarket (matched pairs available if you want same key for both doors)

Order Xpedition-specific locks — Ranger/RZR locks do NOT fit.

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Tools​

• T25 Torx bit
• 10mm socket
• Trim panel tool (plastic)
• Needle-nose pliers or pick
• Flashlight
• Blue threadlocker
• Rag

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Step-by-Step Procedure (No Key Required)​

1. Open the Door​

• Fully open the door
• Support it if you’re working outdoors or on uneven ground

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2. Remove Inner Door Panel​

1. Remove all T25 Torx screws around the inner panel
2. Use a trim tool to carefully pop the panel loose
3. Set the panel aside

Do not pry aggressively — the panel clips are tight but reusable.

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3. Locate the Lock Cylinder Retaining Clip​

• Look behind the exterior door handle
• You’ll see:
  
  • The lock cylinder body
  • A U-shaped spring retaining clip holding it in place

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4. Remove the Retaining Clip​

• Use needle-nose pliers or a pick
• Pull the clip straight back

Important:

• The clip can spring out — cover it with your hand
• Do not bend it; you may reuse it

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5. Remove the Old Lock Cylinder (No Key Needed)​

• Push the lock cylinder outward through the exterior handle
• It slides out without rotating or unlocking

The Xpedition does not require the key to be in any position for removal

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6. Install the New Lock Cylinder​

1. Insert the new cylinder from the outside
2. Ensure:
   
   • Cylinder is fully seated
   • Lock tab aligns with the latch mechanism
3. Reinstall the retaining clip until fully seated

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7. Test the Lock (Before Reassembly)​

• Use the new key
• Verify:
  
  • Lock turns smoothly
  • Door locks and unlocks
  • Handle operates correctly

If stiff or not locking, the cylinder is not seated fully.

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8. Reinstall Door Panel​

• Align panel clips
• Press firmly into place
• Reinstall Torx screws (snug only — no overtightening)

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Optional: Matching Both Doors to One Key​

You have two good options:

Option 1 – Buy a Matched Pair​

• Easiest
• Most aftermarket kits include 2 locks / 2 keys

Option 2 – OEM Re-Key Service​

• Dealer can re-key cylinders to match ignition (VIN-based)
• Requires proof of ownership
• More expensive, but factory-correct

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Common Mistakes to Avoid​

• Forcing the cylinder out (it slides once clip is removed)
• Installing cylinder rotated incorrectly
• Losing the retaining clip
• Slamming door before testing

---

Torque & Specs​

• Door panel screws: Hand snug only
• No torque spec for lock clip (spring-retained)

 

[Crow]

Have no keys for Adv North Star 2024 bought lock kit but instructions are for putting new ones in by using keys .
How do you remove the old ones?

Got if figured out it takes 2 minutes a door do not take anything apart

 

[sscappaticci68]

Got if figured out it takes 2 minutes a door do not take anything apart

please can you explain ?
Thank you

 

[Crow]

please can you explain ?
Thank you

Remove plastic from around lock take a 1/32 hole punch slide it into the lock feel around and push the brass clip down at the back of lock take screw driver around pull out the lock
Basically picking the lock

 

[sscappaticci68]

Remove plastic from around lock take a 1/32 hole punch slide it into the lock feel around and push the brass clip down at the back of lock take screw driver around pull out the lock
Basically picking the lock

thank you