We appreciate all your efforts, Rich. How much did you have to take apart to get to it?
PRETTY MUCH EVERYTHING short of the wheels and tank
started top down
glovebox
black filler plates
right bat cover plastic
rear mid vented pieces
front mid sides w/ flashers
front inner black triangles
unplug sensor from harness on right mid side
upper rad bolts and loco clips(remember how they look take a pic before removing)
lower rad bolt (without doing this you cant move rad enough)
wipe the sensor area well with solvent rag....
now you can reach the sensor bolt....
pop it out, pull the sensor out right side of bike.
Peel the o-ring off with a toothpick, and clean the groove and body well with solvents.
lightly grease new ring with general purpose bearing grease and roll it on, smear a little more on to lube the probe end.
from the left side of bike now,
shove it in and when it stops @ the ring, place your thumb nail against the ring and press it into the groove while pressing the sensor home.
It doesn't require brute force, just some teasing with the thumbnail.
Install everything back in reverse order...
getting the Radiator in place with the clips situated akimbo to the plastic shroud above the horns is the BIOTCH.. requires 4 hands.
you'll figger' it out tho, just relax and expell some good old cussin' words...
I did put a couple wrench clicks on the header nuts, but none were what I could consider "loose" at all...
this whole job goes much easier with a good set of 1/4" drive sockets, long and short extensions, adapters for the allen head bits, and a charged Skil right angle electric driver/wrench.
oh one more tool:
Harbor Freight Bike lift....
this job sucked doing it on the ground....did I mention that?
had I not had another bike on the lift, and more room, I could have taken 2 hours off the job time, just because of access issues and crawling around on the floor....arggggggg
turned a 2 hour job into 4.