Originally Posted by Maytag Repairman
Here is my next project's obstacle. I bought the SW Motech engine guards. The instructions looked easy enough. First, remove a bolt on each side of the bike from the plastic cover(s) at the bottom front. Then on the right side of the bike remove a hose clamp. Next remove the bolt behind the hose. It looks like a hefty bugger. Took a 19mm socket to get on it if I remember correctly. There isn't much clearance between the wrench and the bike and it felt like it was on there pretty tight. I was afraid I might ding something on the side of the bike with the wrench if I had to really but my back into getting it off. It will have to wait until I pick up a socket extension for more clearance. Probably won't find the time to touch it again until Saturday.
I don't remember if it was a 17mm or 19mm (ETA 08-13-12: the bolts are 17mm)
but you will definitely need a short extension to get the correct leverage on it. They are extra-fine threads into aluminum, so apply steady slow pressure with enough leverage (read: a long enough bar) to break them loose. They do not have any thread-locker on them. The crankcase vent hose will be in the way, but you can push it up sufficiently to clear the socket. Did SW-Motech provide longer bolts for the guards to make up for the mounting plate thickness? If not, you may want to read my post on the Givi guards. It seems they mount in the same places, except I think that the Givi guard has a clamp to the frame tubing that the SW Motech does not have.
Oh, and be very careful
reinstalling the two bolts that hold the clutch cable lower bracket and the crankcase vent hose. They do not require very much torque and you can easily strip the aluminum threads in the engine block. I have a factory service manual ordered for the bike but I have not received it yet. It would contain the torque values for the case bolts. Without knowing what the spec torque is, I would just barely snug them. They are not going to cause a leak and they are not going to fall out. The Givi instructions (which were horrible) did not supply the torque spec for either the case bolts or the engine mounting bolts. If you go too loose on either, you can always go back and correct it. If you go too high, there is often only regret.