The core problem is that I had to take off the gas tank and this was the first time I ever took off the gas tank so it took me a while to get everything off. To take off the gas tank, here's what I did:
- Take off the side gas tank panels by unscrewing the one screw at the front that holds them on and popping them out of their rubber donuts that holds the rear part of the panels on.
- Remove the rearmost screws on the side fairing panels (there will be two of them).
- Locate the center fairing strip between the gas tank and the steering column, and the two plastic retainer buttons at the front. Push in the center peg of those buttons until they make a "snap" sound (use a ballpoint pen or something), and remove the buttons.
- Remove the center fairing strip -- the sides just snap under the side fairing, you should be able to pop the side fairings outward a little and it'll just come out.
- Remove the seat
- Grab a 12mm wrench and remove the single bolt holding the back of the tank on
- Take the silver tank prop that serves as the top of the tank mount and lift the tank up enough to prop the tank up with it. DO NOT TRY TO LIFT IT HIGHER THAN THE PROP, there is a stop on the pivot hinge up front that you can damage if you try to lift it against the stop.
- Unplug the fuel gauge wire on the left side
- Unplug the fuel line on the left side
- Unplug the overflow line on the right side (just pop it off the tank)
- Unplug the charcoal canister condensate return line on the right side. (Was easier for me to pop it off the frame mounted fitting than to pop it off the tank, also kept clear which line went where).
- Remove the prop and let the tank back down. Grab a pair of 10mm wrenches (I had one socket wrench and one box-end wrench), and remove the pivot bolt at the front of the tank.
- Lift the tank and slide it backward off its rubber mounts up front, then lift and place aside.
This kit was intended for the left dashboard panel, and was cut to be very slightly longer than required for that purpose. Going rightward and requiring some slack for turning the steering wheel means that I only barely have enough wire to get back to the battery. When I add a fuse panel in the tray behind the battery, I will have to cut off the battery end of this kit and add some longer wires to get to the fuse panel using Posilocks or regular crimp connectors. So it goes.
Now, what took me so long: I was following the directions in the factory service manual, which calls for removing the front side cowling panels also as part of removing the fuel tank. To remove the front side cowling panels, take out all the visible screws. Next you have to remove the chin cowling underneath the headlights. This is done by pushing in the center of a dozen of those button-type fasteners and removing them, then removing two screws hidden deep in the wells of those fake air inlets. You can then wiggle the chin cowling out. Then you'll find out why we had to remove the chin cowling -- there's two more screws hidden behind the chin cowling holding on the side panels. Remove those screws. Then slide the side panels *forward* to get them out of their little rubber donut thingies, and when you feel them "pop" out of the little donut thingy wiggle them out from under the top panel (still sliding forward a bit). Then you'll have a nice open space to work in with no side panels in the way, which I suppose is why the service manual calls for removing these.
Anyhow, it's nowhere near as arduous a process as pulling all the plastics on my old Kawasaki Concours touring bike (now that bike had a lot of plastic on it!), but it was my first time doing it, so I was going very slow and careful. So that's why it took me four hours to do all this yanking of plastics, pulling the tank, running the wire on top of the existing wires, then putting it all back together again, and why I was in my garage until 2am last night. I wanted to ride that bike to work today. And did :-).
-- Badtux the Wrenchin' Penguin