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Thread: Plastic Cover Removal on a 2009 KGT 1300

  1. #31
    Honey Badger Semper_Fi's Avatar
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    The center panel screw
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  2. #32
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    The front one by the Instrument panel area
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  3. #33
    Honey Badger Semper_Fi's Avatar
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    Now pull down onthe tank side panel being aware of the locking features noted in the left side panel
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  4. #34
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    Top Tank Plastic

    The next step is the removal of the top tank cover piece.

    The screws here are all the same length

    Starting from the left front this time remove the screw as shown
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    Last edited by Semper_Fi; 08-13-2009 at 07:48 PM.

  5. #35
    Honey Badger Semper_Fi's Avatar
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    Remove the ones under the battery tray cover
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    Last edited by Semper_Fi; 08-13-2009 at 07:31 PM.

  6. #36
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    Remove the one by the tank fill area
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  7. #37
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    Working your way from the front right side remove the screw shown
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  8. #38
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    Remove the screw by the gas fill
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  9. #39
    Honey Badger Semper_Fi's Avatar
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    Now you are ready to pull up and off with the tank cover.

    NOTE! - there are a group of mating posts around the tank fill area that you should be aware of before just pulling off - they will provide some resistance so gently pull up until they let go and set the panel aside.
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    Last edited by Semper_Fi; 08-13-2009 at 06:11 PM.

  10. #40
    Honey Badger Semper_Fi's Avatar
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    At this point with the top and side plastics removed you have access to all the engine and engine related peripherals

    Left side
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    Last edited by Semper_Fi; 08-13-2009 at 07:50 PM.

  11. #41
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    Right Side
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    Last edited by Semper_Fi; 08-13-2009 at 07:50 PM.

  12. #42
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    As stated earlier you will need to store the removed plastic while working on the bike.

    I stored mine where I usually store the bike lift - it is out of the way and enough room to not crowd the parts
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  13. #43
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    Bottom Skirt Plastic

    To remove the bottom skirts you do not need to remove the two side panels - however you do have to remove the 3 screws on the bottom of each of the side panels, and then one from the frame.

    The picture shows the screw to be removed from the left side - the same screw is removed for the right side panel, in addition to the 3 from its mating side panel.
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  14. #44
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    Then remove the 2 bottom T-25's (12mm long) and then you can remove these panel(s)
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    Last edited by Semper_Fi; 08-13-2009 at 07:51 PM.

  15. #45
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    Assembly Help

    What you have just reviewed was the documentation of my first time removing the plastic on a KGT.

    It was not a big deal - the most important part is keeping track of where the various size screws go - luckily they are all the same type!!

    However one thing noticed is that the parts fit into each other - there are a lot of instances of this and I showed the major ones.

    Shown in the next few images are those that you should be aware of to facilitate the reassembly process.

    VERY IMPORTANT NOTE - if you are FORCING anything STOP - the bike is very well designed and if the piece is in the right place it will drop right in.
    Last edited by Semper_Fi; 08-13-2009 at 07:52 PM.

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