Side Covers

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Middle Cover

Remove the seat. See the Seat topic for more information.

Remove the battery. See the Battery topic for more information.

Remove the two quick release pins on the 2005 and newer 650 models with a flat head screwdriver or the ignition key.

Remove the air cleaner upper cover by pulling it back and off.

The 700 and older 650 models have a single quick release pin at the base of the cover and two pivot pins at the front.  

Release the pin and pivot the cover up on the 700 and older 650 models.

Position the shift lever knob in the neutral position.

Loosen the shift lever knob locknut with a 12 mm wrench. Take off the shift lever knob.

Remove the mounting screws and washers on both sides with a #3 Phillips screwdriver.

Remove the two clips.

Remove the two upper mounting screws and washers with a #3 Phillips screwdriver.

Remove the middle cover.

Left Side Cover

Remove the middle cover. See the Side Covers topic for more information.

Remove the front mounting screw with a #3 Phillips screwdriver.

Remove the rear mounting screw with a #3 Phillips screwdriver.

Remove the left side cover and the damper on the frame.

Installation

Left Side Cover

Install the damper on the frame. Install the left side cover and align the mounting screw holes.

Install the rear mounting screw with a #3 Phillips screwdriver.

Install the front mounting screw with a #3 Phillips screwdriver.

Middle Cover

Install the middle cover and align the tabs and mounting screw holes.

Install the two upper mounting screws and washers with a #3 Phillips screwdriver. Tighten the screws securely.

Install the two clips.

Install the mounting screws and washers on both sides with a #3 Phillips screwdriver. Tighten the screws securely.

Install the shift lever knob and tighten the lock nut to specification with a 12 mm wrench.

Fastener	Torque
	N-m	kgf-m	ft-lb
Grip hold nut	9.8	1.0	87 in-lb

Install the battery. See the Battery topic for more information.

Align the tabs of the air cleaner upper cover and install it on the 2005 and newer 650 models.

On the 700 and 2002 – 2003 650 models pivot the cover into place.

Install the quick release fastener/s with a flat head screwdriver or the ignition key.

Install the seat. See the Seat topic for more information.