Ok I know this has been written up before but I wrote this up for a friend so I decided to post it here too.
There's a bunch of the little push/pull rivets for the plastic. Go here for a complete layout:
https://www.st-owners.com/forums/showthread.php?73238-ST1300-TupperWare-Worksheet
Since this is the first time you're taking the bike apart I recommend putting all screws back in the hole they came out of if possible. This helped me memorize where they all went. If someone has taken it apart before they may not be in the right places but at least they fit somehow in those spots.
Here's all you need:
#2 Phillips screwdriver
5mm hex (T handle works great for this but some bolts have shallow heads so press hard)
8mm nutdriver or socket
Here's the order (Diagram on page 58 of the Service Manual PDF, or Page 2-2 by the manual's page number)
1. Remove Mirror Housing
2. Remove Lower Cowl
3. Remove Inner Cowl
4. Remove Lower Inner Cowl
5. Remove Tip Over Wing
6. Remove Middle Cowl
1. Remove the mirror housing. It pops off and it's held in place by spring clips. It also has a tether. (You don't need to remove the mirror. Just the housing)
- Hold the front of the mirror housing (the side with the blinker lense) in one hand. Then with a swift movement hit the outer point of the mirror housing with your other hand. Hit the mirror housing so that you're striking it on the mirror side moving towards the front of the bike. It will pop right off. You do basically the reverse to put it back on except you hit it on the tip aiming towards the bike. It's easier to show than explain but you'll get it. I usually line up the top two posts, smack them on, then do the bottom post. You have to smack is pretty hard sometimes. Don't be shy.
- The mirror housing has a tether. You can unscrew it from the mirror but be careful not to let it fall into the fairing. Or you can pop it out of the fairing without unscrewing it but that is a little trickey. For the first go around I would just unscrew it and then make sure it stays in place.
2. Remove the lower cowl
- Just remove all the push rivets on the underside of the lower cowl at the front of the bike. That way you're not guessing which ones to remove. There's about 5 of them.
- Then remove the 5 allen bolts along the lower cowl. 2 are narrower then the other 3 and 2 of the wider ones have shoulders. The third doesn't.
- Last remove the one push rivet that is near your ankle if you were sitting on the bike. Leaving this push rivet in place makes it easy to remove without having to hang on to it. Put this rivet in first when putting it back on so you don't have to hold it in place. You push the center of the rivet in with a screwdriver tip or something and then grab around the head to pull it out. To put it back in you push the center pin so the head is sticking out of the push pin and the forked teeth are flat. Put the rivet in the hole and then push the center pin in with your finger to lock it into place.
3. Remove the inner cowl
NOTE: If you are removing the right inner cowl there is a temperature sensor connected to it. There is a molex connector on the wire harness that you can remove and leave the sensor on the inner cowl. However some people find it easier to just remove the screw holding the sensor to the inner cowl.
- There are 4 push rivets along the edge of the inner cowl as it follows the middle cowl and one screw. One is up under the headlight assemebly. Three of the push rivets have bigger heads then the forth so they are easier to grab. The one with the shallower head is the one that goes in up by the screw under the headlight assembly. Remove the screw also.
- Then there are 2 push rivets on the top of the inner cowl which can be felt if you are standing beside the bike and reach around the inside corner of the fairing pocket up by the top triple clamp on the bike. You may have to turn the handlebars to get to them. You push the center of the rivet in with a screwdriver tip or something and then grab around the head to pull it out. To put it back in you push the center pin so the head is sticking out of the push pin and the forked teeth are flat. Put the rivet in the hole and then push the center pin in with your finger to lock it into place.
4. Remove the lower inner cowl (technically you only have to remove the screw and push rivet for the side you're removing).
- This is the piece right behind the front wheel. There's two push rivets and two screws. Just remove the rivet and screw on the side you're taking off. You may need a stubby screwdriver for the screws on this one.
5. Remove the tip over wing
- Remove the 5mm allen on the underside of the wing. Then pull the wing off by grabbing the rear of the wing and pulling straight out. It hinges on a catch on the front of the wing.
NOTE: This allen screw is different from all the others. Don't get it confused!!!
- Since you're here remove the 2 8mm bolts on either side that are underneath the wing. Remove the bushings too if they don't stay in place.
6. Finally, remove the middle cowl
- Once you've got all the other crap off there are two screws in a horizontal line below the mirror to remove
- Then remove the two screws that are under the fairing pocket lid towards the front of the pocket
- Now remove the one 5mm allen that is in the center of the cowling just above the valve cover.
NOTE: This allen screw is different than all the rest. Don't confuse it with any of the others. It is also not the same as the one for the tip over wing. You have been warned.
- There are a couple catches by the mirror and the headlight assembly. Make sure you don't break them. I usually pull the rear of the cowling out a little first and then work my way forward. Make sure the fairing pocket is open. The hinge on the fairing pocket will prevent you from pulling the cowling straight off so focus on getting around then the continue working forward.
NOTE: When putting the left middle cowl back on make sure that the wiring harness connector is tucked into it's holder on the fairing pocket.
NOTE: When putting the cowling back on work from the front to the rear. Put the catches in place then work around the fairing pocket hinge and then place the post at the rear of the cowling in it's hole. Then put in the one 5mm allen in the center of the cowling just above the valve cover. That will hold it in place while you line everything else up. Once that's done you can start putting things back together.
There's a bunch of the little push/pull rivets for the plastic. Go here for a complete layout:
https://www.st-owners.com/forums/showthread.php?73238-ST1300-TupperWare-Worksheet
Since this is the first time you're taking the bike apart I recommend putting all screws back in the hole they came out of if possible. This helped me memorize where they all went. If someone has taken it apart before they may not be in the right places but at least they fit somehow in those spots.
Here's all you need:
#2 Phillips screwdriver
5mm hex (T handle works great for this but some bolts have shallow heads so press hard)
8mm nutdriver or socket
Here's the order (Diagram on page 58 of the Service Manual PDF, or Page 2-2 by the manual's page number)
1. Remove Mirror Housing
2. Remove Lower Cowl
3. Remove Inner Cowl
4. Remove Lower Inner Cowl
5. Remove Tip Over Wing
6. Remove Middle Cowl
1. Remove the mirror housing. It pops off and it's held in place by spring clips. It also has a tether. (You don't need to remove the mirror. Just the housing)
- Hold the front of the mirror housing (the side with the blinker lense) in one hand. Then with a swift movement hit the outer point of the mirror housing with your other hand. Hit the mirror housing so that you're striking it on the mirror side moving towards the front of the bike. It will pop right off. You do basically the reverse to put it back on except you hit it on the tip aiming towards the bike. It's easier to show than explain but you'll get it. I usually line up the top two posts, smack them on, then do the bottom post. You have to smack is pretty hard sometimes. Don't be shy.
- The mirror housing has a tether. You can unscrew it from the mirror but be careful not to let it fall into the fairing. Or you can pop it out of the fairing without unscrewing it but that is a little trickey. For the first go around I would just unscrew it and then make sure it stays in place.
2. Remove the lower cowl
- Just remove all the push rivets on the underside of the lower cowl at the front of the bike. That way you're not guessing which ones to remove. There's about 5 of them.
- Then remove the 5 allen bolts along the lower cowl. 2 are narrower then the other 3 and 2 of the wider ones have shoulders. The third doesn't.
- Last remove the one push rivet that is near your ankle if you were sitting on the bike. Leaving this push rivet in place makes it easy to remove without having to hang on to it. Put this rivet in first when putting it back on so you don't have to hold it in place. You push the center of the rivet in with a screwdriver tip or something and then grab around the head to pull it out. To put it back in you push the center pin so the head is sticking out of the push pin and the forked teeth are flat. Put the rivet in the hole and then push the center pin in with your finger to lock it into place.
3. Remove the inner cowl
NOTE: If you are removing the right inner cowl there is a temperature sensor connected to it. There is a molex connector on the wire harness that you can remove and leave the sensor on the inner cowl. However some people find it easier to just remove the screw holding the sensor to the inner cowl.
- There are 4 push rivets along the edge of the inner cowl as it follows the middle cowl and one screw. One is up under the headlight assemebly. Three of the push rivets have bigger heads then the forth so they are easier to grab. The one with the shallower head is the one that goes in up by the screw under the headlight assembly. Remove the screw also.
- Then there are 2 push rivets on the top of the inner cowl which can be felt if you are standing beside the bike and reach around the inside corner of the fairing pocket up by the top triple clamp on the bike. You may have to turn the handlebars to get to them. You push the center of the rivet in with a screwdriver tip or something and then grab around the head to pull it out. To put it back in you push the center pin so the head is sticking out of the push pin and the forked teeth are flat. Put the rivet in the hole and then push the center pin in with your finger to lock it into place.
4. Remove the lower inner cowl (technically you only have to remove the screw and push rivet for the side you're removing).
- This is the piece right behind the front wheel. There's two push rivets and two screws. Just remove the rivet and screw on the side you're taking off. You may need a stubby screwdriver for the screws on this one.
5. Remove the tip over wing
- Remove the 5mm allen on the underside of the wing. Then pull the wing off by grabbing the rear of the wing and pulling straight out. It hinges on a catch on the front of the wing.
NOTE: This allen screw is different from all the others. Don't get it confused!!!
- Since you're here remove the 2 8mm bolts on either side that are underneath the wing. Remove the bushings too if they don't stay in place.
6. Finally, remove the middle cowl
- Once you've got all the other crap off there are two screws in a horizontal line below the mirror to remove
- Then remove the two screws that are under the fairing pocket lid towards the front of the pocket
- Now remove the one 5mm allen that is in the center of the cowling just above the valve cover.
NOTE: This allen screw is different than all the rest. Don't confuse it with any of the others. It is also not the same as the one for the tip over wing. You have been warned.
- There are a couple catches by the mirror and the headlight assembly. Make sure you don't break them. I usually pull the rear of the cowling out a little first and then work my way forward. Make sure the fairing pocket is open. The hinge on the fairing pocket will prevent you from pulling the cowling straight off so focus on getting around then the continue working forward.
NOTE: When putting the left middle cowl back on make sure that the wiring harness connector is tucked into it's holder on the fairing pocket.
NOTE: When putting the cowling back on work from the front to the rear. Put the catches in place then work around the fairing pocket hinge and then place the post at the rear of the cowling in it's hole. Then put in the one 5mm allen in the center of the cowling just above the valve cover. That will hold it in place while you line everything else up. Once that's done you can start putting things back together.