Special Tools

Description	Part Number	Qty.
DIGITAL TECHNICIAN II	HD-48650	1

PREPARE

1.	Remove top cover. See Chassis → TOP COVER.
2.	Deactivate electrical system. See Electrical → POWER DISCONNECT.
3.	Remove fairing. See Chassis → FAIRING.
4.	Loosen handlebars and position out-of-way. See Chassis → HANDLEBAR. NOTE Note position of handlebars before loosening.

REMOVE

1.	See Figure 1. Rotate IM (1) to the most rearward position. NOTE Rotating the IM rearward aligns the keyways in both brackets.
2.	Discard torque hinges (3). a. Using a 6.4 mm (0.25 in) flat tip drive punch. Align the punch to the torque hinge in the IM (1) bore (2). NOTE Verify that the drive punch is flat tipped. If using a sharped tip punch, may cause the torque hinge to expand causing difficulty to remove. b. Drive the pair of torque hinges out of the opposite side of the bore and discard.
3.	Remove IM. a. Disconnect IM connector (1). b. Remove IM.

INSTALL

1.	See Figure 2. Connect the IM connector (1).
2.	Position IM on upper handlebar clamp (3). a. Verify that the keyways (2) are aligned.
3.	See Figure 3. Install new torque hinges. NOTE Install the inner side (2) of the new torque hinge into IM bore. The torque hinges are installed from the two outer sides of the IM. a. Align keys (3) on new torque hinge. b. See Figure 4. Position new torque hinge (1) into bore. c. Using a 12.7 mm (0.50 in) flat tip drive punch. Drive new torque hinge into place. NOTE The outer side of the new torque hinge is fully seated when flush with the IM bracket. d. Position new torque hinge (2) into place. Drive new torque hinge into place.

1	Instrument Module (IM)
2	Bore
3	Torque hinge

Figure 1. IM and Torque Hinge

1	IM connector
2	Keyway
3	Upper handlebar clamp

Figure 2. Torque Hinge Keyway

1	Outer sides
2	Inner sides
3	Keys

Figure 3. Torque Hinge Pair

1	First torque hinge
2	Second torque hinge

Figure 4. Installing Torque Hinges

COMPLETE

1.	Position handlebar back. Tighten. See Chassis → HANDLEBAR.
2.	Install fairing. See Chassis → FAIRING.
3.	Activate electrical system. See Electrical → POWER DISCONNECT.
4.	Install top cover. See Chassis → TOP COVER.
5.	Perform module replacement procedure using Digital Technician II. Special Tool: DIGITAL TECHNICIAN II (HD-48650)