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- 1). Unscrew the bolt on the bottom edge of the left side cover, located below the front seat and fuel tank, using a 5 mm Allen wrench. Pull the cover away from the frame's mounting grommets, and then slide the cover toward the front of the motorcycle to remove it completely. Remove the right side cover, using the same method.
- 2). Unscrew the mounting bolts from the sides of the front seat, using a 5 mm Allen wrench. Lift the rear of the seat slightly, and then pull it towards the passenger seat until the hook under the front of the seat is free from the motorcycle's frame.
- 3). Remove the plastic rivets from the bottom of the lower fairing to separate the fairing panels. Use the tip of a 5 mm Allen wrench to depress the center of the rivet, and then pull the rivet out of the fairing. Unscrew the lower fairing mounting bolts, using a 5 mm Allen wrench, and then pull the fairing panels away from the motorcycle.
- 4). Set the fuel tank valve, located under the left side of the tank, to the "On" position. Unscrew the pair of bolts at the base of the fuel tank, using a socket wrench and a 10 mm socket. Lift the base of the tank up, then reach under the tank and unplug the fuel level sender connector. Pull the vacuum hose off the bottom of the tank and remove the fuel line from the fuel valve outlet. Pull the fuel tank away from the handlebars, and then set it aside.
- 5). Unscrew the handlebar mounting bolts from the upper fork clamp, using a 6 mm Allen wrench. Lay the handlebars over the top of the motorcycle's frame, where the fuel tank normally mounts, to avoid damaging the brake hose and clutch cable.
- 6). Loosen the pinch bolts on both sides of the upper fork clamp, using a 6 mm Allen wrench. Unscrew the steering clamp nut, using a socket wrench and a 22 mm socket. Lift the upper fork clamp off of the front fork, using a rocking motion. Follow the ignition switch wiring from the upper fork clamp to its connector, positioned along the side of the motorcycle's frame. Unplug the ignition switch connector.
- 7). Mount the upper fork clamp in a vise, bottom facing up to provide access to the ignition switch security bolts.
- 8). Punch an indentation into the center of both security bolt heads, using a center punch. Drill the security bolt heads out of the upper fork clamp, using a 1/4-inch drill bit and an electric drill. Stop once the bolt head separates from the rest of the bolt. Slide the ignition switch off of the upper fork clamp. Unscrew the remaining portion of the security bolts with vise-grip pliers.
- 9). Place the new ignition switch onto the bottom of the upper fork clamp. Coat both of the M6-by-16 mm security Torx bolts' threads with a semi-permanent thread-locking compound. Screw the bolts into place, using a nut driver and a TR20 Security Torx bit.
- 10
Plug the new ignition switch connector into the motorcycle's wiring harness. Push the upper fork clamp onto the front fork. Screw the fork clamp bolt into place by hand. Tighten it to 32 foot-pounds, using a torque wrench and a 22 mm socket. Tighten both pinch bolts to 15 foot-pounds, using a torque wrench and a 6 mm Allen socket. - 11
Slip the rubber bosses at the front of the fuel tank into the catches built into the frame, near the front fork. Push the vacuum hose and fuel line into place and reconnect the fuel level sender connector. Lower the fuel tank to the frame. Screw the fuel tank mounting bolts into place, using a socket wrench and a 10 mm socket. - 12
Reinstall the lower fairing panels onto the motorcycle. Screw the fairing mounting bolts into place, using a 5 mm Allen wrench. Push the plastic rivets into the bottom of both fairing panels. - 13
Slide the seat hook into the slot built into the frame, below the fuel tank. Screw the seat mounting bolts into place, using a 5 mm Allen wrench. - 14
Slide the left side cover into the slot cut into the rear fairing, and then push the cover's tabs into the frame's mounting grommets. Screw the mounting bolt into place at the bottom of the side cover, using a 5 mm Allen wrench. Reinstall the right side cover, following the same method.
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