(Just an FYI this is a work in progress, was unsure if I can change the title later.. so didn't add "W.I.P.")
I figured i'd start off by listing out the process i'll follow and will add more information, videos, images as applicable. I have included the sections found in the service manual [ ex: (2-16) ] and paraphrased the disassembly instructions. The majority of the assembly process is just the disassembly in reverse. You don't have to follow this, it just might help some new to bike work and/or mods. Though I can't stress this mod is NOT for the squeamish or timid. You will be disassembling much of your bike and placing your headlight assembly in your home oven or baking it with a heat gun!!
Do proceed with caution. I am not responsible for any mis-use, injury, death, pissed wives, burnt ovens,
melted headlights, severed fingers or any other undesirable results from following this guide.
For a quick recap. I will be installing the BKMoto 6000k HID kit for the 500r
that was just released (in Late August 2013) with white angel eyes front/back. Blue led strips (maybe) and blue or white LED bulb in the forward upper light pod.
I HIGHLY recommend you buy the service manual, the diagrams and disassemly/assembly guides are priceless.
More images will be added
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1. Remove the rear seat
Put key in, pop off (simplest thing you'll do all day!)
Remove the front seat
Remove two bolts and pull seat off
Remove side cover
Remove the trim clip and socket bolt. Release the 2 grommets from the bosses of the rear cowl, and two tabs from the footpeg bracket and rear cowl
Remove the middle cowls
Remove the trim clips, socket bolt and 3 setting socket bolts. Release the snap fit clip, release the hook/loop fastening. Release the meter panel and middle cowl from the bolt hole stud on the fuel tank. Press the meter panel inward and relase the 6 side tabs while spreading the the middle cowl slightly. Release the 3 front tabs and the turn signal light 3P connector.
Remove meter panel
First, remove the mirrors. Remove the band clip from the meter panel. Disconnect the front sub-wire harness 4P (Black) and 12P (Black) connectors. Cover the front fender from scratching/denting!! Loosen the lower mounting nut of the cowl stay. Remove the upper mounting nut and the bolt then the rest the front cowl assembly on the fender. Position the front cowl assembly so the meter panel doesn't mess with the handlebars.
Remove front cowl
Hold the front cowl assemlby and remove the cowl stay lower mounting nut and bolt. Then remove it.
Too many steps to paraphrase, see image:
Remove headlight assembly
At this point you should have removed the front cowl/windscreen assembly. If not, go do that now. Next, remove the headlight 4P (Black) connector from the stay and disconnect it. Remove the 6mm washer-bolt (lower) and two 5mm washer-bolts (upper)
Additional disassembly, not "required"
Be sure to keep all the bolts, washers, grommets, clips, fasterers and other parts in a safe location. I like to mark each section on a zip-lock and place the items in there for safe keeping.
As of right now 12 pm EST on Saturday August 31st 2013
i'm still waiting for my HIDs to be delivered. Once that happens i'll continue with this guide. Until then happy modding and let me know if you have any questions.