Question about 2006 Suzuki DL 650 V-Strom

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I'm trying to remove the Left Side/front cowling body panel.....

....to get a small spot touched up where the paint rubbed off. There seems to be a few fasteners on the cowling (both front and side), that are like small plastic round fasteners, with a small round circular piece in the middle. I can't figure out how to remove these without breaking them? Do I need a special tool? Also, I cant figure out if I also need to remove the frot cowling to get the side off, and iof there are any other body panels that need to be removed......any help or advice is much appreciated.

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  • dps1 Apr 10, 2009

    I scratched up the left side cowling of my '08 DL1000 V-Strom and have purchased a replacement on-line. I want to save $ by switching it out myself. I have the cowling loose near the tank and bottom, but I can't get it loose from the front. Help!

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  • Master
  • 948 Answers

Those are called "tray clips" If you look at the microfiche at Ron Ayers you can see a drawing that shows where they go, but not how to remove them easily. The center piece snaps into place, but does not come out easily unless you can push from the opposite side. I've had luck putting in a small screw a few turns, then pulling on it. They will pop out with some effort, but don't pull so hard you damage the bodywork. If the bodywork is moving a lot due to your efforts something is wrong.

Posted on Jan 26, 2009

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1 Answer

How to remove the heater core. It is a 1999 Mercury Grand Maquis GS


Below are directions. It is a fairly big job has the entire dash has to come out:


  • If equipped, turn the air suspension service switch to the OFF position before raising the vehicle.
  • Drain the cooling system.
    • Remove or disconnect the following:

      Negative battery cable
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    • Rear airflow duct
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      SRS module-to-steering wheel bolts, from both sides of the steering wheel.
    • SRS module and disconnect the electrical connector
    • Horn switch electrical connector
    • Remove the passenger-s side SRS module by removing or disconnecting the following:

      Open the glove box and disconnect the glove compartment isolator
    • Push inward on the 2 glove box door tabs and lower it
    • SRS module-s electrical connector
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    • Remove the instrument panel by removing or disconnecting the following:

      Speed control servo nuts and move the servo aside
    • Bolt and disconnect the left side bulkhead connector
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    • Blower motor electrical connector
    • Air conditioning pressure cut-off switch electrical connector
    • In-line electrical harness connector
    • Electronic Automatic Temperature Control (EATC) variable blower motor controller electrical connector
    • Right front wheel
    • Right front fender splash shield bolts and move the shield away from the cowl
    • Wiring harness from the evaporator case
    • Wiring harness from the cowl
    • Right side instrument panel lower insulator pushpins, disconnect the power point electrical connector, remove the courtesy lamp from the socket and remove the insulator
    • Unseat the wiring grommet and feed the wiring harness through the cowl
    • Cowl side trim panels and the windshield side garnish moldings from both sides
    • Locking clip and the Electronic Crash Sensor (ECS) module electrical connector
    • Antenna connector
    • Ground wire bolts from the right side
    • EATC hose at the evaporator housing
    • Bolt and disconnect the bulkhead connector from the right side
    • Pull the door weatherstrip seals away from the instrument panel on both sides
    • Tunnel brace trim cover
    • Climate control head vacuum harness connector
    • Instrument panel tunnel brace nuts and the brace
    • Ground wire bolts from the left side
    • Wiring harness connectors from the left side
    • Parking brake switch electrical connector
    1. Pry out the instrument panel defroster opening grille, disconnect the electrical connectors and the remove the grille.

    • Remove or disconnect the following:

      3 upper instrument panel screws
    • Instrument panel cowl side nut from both sides
    • Instrument panel cowl side bolt from the left side
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    Section 01-12: Instrument Panel 1997 Crown Victoria/Grand Marquis Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 05/16/2000
    Instrument Panel SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Radio Removing Tool T87P-19061-A
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    1. Raise vehicle on hoist.
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      r11570a.gif


      Item Part Number Description 1 04320 Instrument Panel 2 N807296-S Cap 3 388577-S Push Pin (6 Req'd) 4 043A88 Instrument Panel Lower Insulator, RH 5 043A89 Instrument Panel Lower Insulator, LH 6 - Module Bracket (Part of Module) 7 13466 Miniature Bulb 8 043A88 Instrument Panel Lower Insulator, RH 043A89 Instrument Panel Lower Insulator, LH
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      r11573b.gif


      Item Part Number Description 1 044A90 Instrument Panel Upper Finish Panel 2 04320 Instrument Panel 3 04268 Instrument Panel Upper Moulding, RH 4 06081 Glove Compartment Lock Set 5 061A40 Glove Compartment Door Cover 6 N807122-S411 Screw (2 Req'd) 7 N807122-S411 Screw (10 Req'd) 8 - Parking Brake Release Handle (Part of 2780) 9 04459 Instrument Panel Steering Column Cover 10 04502 Instrument Panel Steering Column Opening Cover Reinforcement 11 04389 Instrument Panel Moulding, LH 12 044D71 Instrument Panel Cluster Finish Panel A - Tighten to 2.1-2.9 Nm (19-25 Lb-In) B - Tighten to 4-6 Nm (36-53 Lb-In)
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      Instrument Panel


      r11571a.gif


      Item Part Number Description 1 N802539-S100 Nut (5 Req'd) 2 383554-S100 Rivet (2 Req'd) 3 01631 Vehicle Identification Plate 4 01544 Brake Pedal Support 5 N805632-S36 Bolt 6 N800854-S2 J Nut (2 Req'd) 7 N806030 Stud 8 N602480-S55 Nut 9 04320 Instrument Panel 10 N807122-S411 Screw (5 Req'd) 11 - Steering Column Retaining Nut 12 - Bolt (Part of 3F659) 13 3F659 Brake Pedal Support Steering Column Brace 14 N606675-S2 Bolt (3 Req'd) 15 04502 Instrument Panel Steering Column Opening Cover Reinforcement 16 N806067-S2 Bolt (2 Req'd) 17 N620482-S36 Nut 18 N801366-S2 Stud 19 045D56 Instrument Panel Cowl Brace 20 N606115-S100 Bolt (3 Req'd) A - Tighten to 9-14 Nm (80-123 Lb-In) B - Tighten to 10-14 Nm (89-123 Lb-In) C - Tighten to 2-3 Nm (18-26 Lb-In) D - Tighten to 47-63 Nm (35-46 Lb-Ft) E - Tighten to 45-70 Nm (34-51 Lb-Ft) F - Tighten to 22-34 Nm (17-25 Lb-Ft)
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