Top Enclosure Removal

 
  Tools you will need:
  1. 5 & 6 mm allen wrench
  2. 10mm socket wrench
  3. phillips screwdriver
  4. large straight screw driver
  5. magnet

Step #1:

Dash panel removal

Remove the speaker covers by pushing down on the top lip and pulling toward the rear. They pop off real easy so you don't need to use much force.

 

Pull out the plastic pin at the top corner of the speaker housing - pulls up about 1/8 inch.

 

 

Remove the two lower metric allen screw (5 mm) If you have a magnet probe like the one shown use it to remove the screws or you can magnetize a screwdriver and use that.

Remove the key trim piece it just pulls up and removes easily. Remove the two phillips screws.

 

 

The dash panel will come loose now except for the single wire under the Mode switch panel - use a small screw driver to open the latch on the connector and pull it apart - This is the hardest part of this whole job - this single connector must hold the entire frame together - at least that is the way it is designed. You may elect to snap off the latch so it is easier next time - your call.

Step #2

Trim strip and seat removal - Trim strip just pull right off. Grab it at the very bottom and gently pull, it should peal off very easily so no force is required. Seat is also easy just remove the handle screws (6 mm allen bolts) grab the back of the seat, fold the filler cushion forward and lift the back of the seat first. You have to bend it around the back cushion some but it pulls up pretty easy.

Step #3

 

 

Remove the (4) 5 mm screws making sure to keep track of where they came from as they are all different and must go back into the correct spot.

 

These screws should not be to tight - only snug as they strip out easily so keep that in mind when replacing them.

 

 

 

 

 

 

 

 

Don't miss the top screw next to the inside edge of the speakers. Should be (5) screws each side total. Also pay close attention to how the top edge fits under the rubber grommet at the windshield lever. That can be tricky to get back in place later.

 

 

One 10mm nut on each side holds the rear of the enclosure.

 

 

 

 

 

 

Here the enclosure is off - lift it slowly rear first and slide it back a bit so you can lift it and unhook the various electrical connections.

Here you can see the ECM Cruise control and mass of wiring

Air filter is located under the Cruise and ECM

 

Air Cleaner removal and replacement is back in the EPSS manual on the main page.

BACK

NK 10/26/2003