Has anybody changed one out and what is involved?
Hey Robin,
It isn't that difficult but does take some swearing.
While you don't have to remove the tank, it make the process a little easier because it gives you more angles to get at things. It will also get the petcock handle out of the way giving you more room to move around.
You will also want to protect the center cover from the motor/alternator or you could end up with scrapes. Painters Masking Tape works pretty good for this. Just apply it down low enough to cover the motor parts. Otherwise, you can put a rag over the motor.
Work from the left side of the bike for the most part. You will have more access to everything.
Steps are as followed.
1) Remove the two screws into the frame (under the side covers). Do not lose the little bushing washer that is under the cover. These keep you from over tightening the screws and busting the cover.
2) Wiggle the cover up until it pops out of the holder at the bottom. This may take a little effort and time...and usually where the cussing comes into play.
3) Remove the seat lock from the cover. You will need to slide out the spring clip, undo the cable, and slide the lock out of the cover. You could leave the lock in place on the cover but you have to get the cable off and I think it is easier to do this with the lock free.
4) Remove the bank senor. Pay close attention to how this is mounted. Get it upside down and your bike won't start. I usually pull the cover out a little and can get a screwdriver on one screw. Then rotate the sensor to give enough room to get the other screw. I don't think you can get to the connector to undo it...but if you can...that is the preferred method.
5) Pull the cover out.
Installation is the reverse of the above.
Hope this helps.
Joe