3. During installation, press the cover until the slot
on the top left edge engages the grommet, then turn
the key counterclockwise.
TOOLBOX PANEL
Removal/Installation
Refer to
Figure 10
.
CAUTION
Several hoses are disconnected from
various fittings during this procedure.
Label each hose and its fitting so they
can be easily identified during assem
bly. Every hose must be reconnected to
the correct fitting during assembly.
The same applies to electrical connec
tors. Label each connector and its har
ness mate as they are disconnected.
Also note how the hoses and wires are
routed along the toolbox panel. They
must be rerouted along the same path.
1. Remove the toolbox cover and the left side cover
as described in this chapter.
2. Remove the battery as described in Chapter Three.
3. Remove the fuse holder as follows:
a. Disconnect the electrical connectors (
Figure
11
) from the fuse holder.
b. Pull the fuse holder damper from the tang on
the toolbox panel.
4. On models with an AIS system, remove the AIS
assembly as described in Chapter Eight.
5. Remove the tool kit from the toolbox.
6. Remove the mounting screws (A,
Figure 12
)
and lift the hose bracket (B) from the toolbox panel.
Note how the hoses behind this bracket are routed
along the toolbox panel (
Figure 13
). They must be
rerouted along the same path during assembly.
7. On California models, perform the following:
a. Disconnect the purge hose (A,
Figure 13
) from
the lower hose fitting on the EVAP solenoid
valve.
b. Disconnect the two-pin electrical connector
from the EVAP solenoid valve (B,
Figure 13
).
c. Disconnect the fuel tank hose (C,
Figure 13
)
from the EVAP rollover valve. This valve can be
found just forward of the EVAP solenoid valve,
behind the fuel pump hoses. See D,
Figure 13
.
8. Disconnect the fuel pump inlet hose (A,
Figure
14
) and its outlet hose (B) from their fittings on the
fuel pump.
9. Roll back the boot that protects the electrical con-
nectors and disconnect the black, two-pin fuel pump
connector (C,
Figure 14
) from its harness mate.
10. Disconnect the remaining electrical connectors
from their harness mates:
a. Three-pin speed sensor connector (A,
Figure
15
).
b. Blue, two-pin sidestand switch connector (B,
Figure 15
).
c. Three-pin stator connector (C,
Figure 15
).
d. Two-pin pickup coil connector (D,
Figure 15
).
e. Neutral switch bullet connector (E,
Figure 15
).
11. Remove the bolt (
Figure 16
) that secures the
battery box to the toolbox panel.
12. Make sure all hoses and electrical connectors
are released and moved safely out of the way.
13. Remove the toolbox panel screws (
Figure 17
)
and lift the toolbox panel from the motorcycle.
14. Installation is the reverse of removal. Note the
following:
a. Make sure each electrical connector is con-
nected to its original harness mate.
b. Connect each hose to its original fitting.
c. Route the hose and electrical cables along the
original path noted during removal.
BATTERY COVER
Removal/Installation
1. Remove the battery cover bolt (
Figure 18
).
2. Grasp the cover and pull it out from the frame
until the cover’s slots in the rear side disengage
from their grommets.
3. Remove the cover.
384
CHAPTER FOURTEEN
9
