How to Replace the Key to a Yamaha V Star 650by Chris Gilliland
As delivered from the dealership, a Yamaha V Star 650 is provided with a pair of ignition keys and a metal tag with a key code. The code allows the V Star's owner to order a new set of keys matched to the motorcycle's ignition switch in case they're lost. But the key code tag is easily lost, especially if the motorcycle is purchased used. As an added form of insurance, the key code is also imprinted into the ignition switch housing, which can be removed and taken to your Yamaha dealership to verify you are the motorcycle's rightful owner.
Remove the passenger and rider seats from the motorcycle using a 10 mm socket and a socket wrench.
Remove all three bolts attaching the speedometer bezel to the fuel tank using a 4 mm Allen wrench. Lift the speedometer off of the fuel tank, then unplug the electrical connectors.
Remove the bolts on each side of the lower fuel tank bracket, located at the base of the fuel tank, using a 12 mm socket. Turn the fuel tank valve, located under the left side of the tank, to the "Off" position. Lift the base of the fuel tank off of the motorcycle's frame, then pull the fuel hose off of the valve using pliers. Pull the fuel tank toward the rear of the motorcycle until it can be removed completely.
Remove the bolt from the right steering neck cover, located along the right side of the frame near the steering pivot, using a 12 mm socket. Pull the cover off the frame to expose the ignition switch.
Drill through the ignition switch security bolts, using an electric drill and a 1/4-inch drill bit, until the bolt heads fall off. Pull the ignition switch off of the bolt shanks, then unplug the switch connector from the motorcycle's wiring harness. Remove the bolt shanks using locking pliers.
Take the ignition switch to a Yamaha repair center. The parts department will use the key code imprinted into the ignition switch housing to order a new key set specific to the ignition switch.
Coat the threads of two 10 x 20 mm Allen head bolts with semi-permanent threadlocking adhesive after you have the new keys . Mount the ignition switch onto the motorcycle's frame using a 4 mm Allen wrench. Plug the ignition switch connector into the motorcycle's wiring harness.
Mount the right steering neck cover onto the motorcycle's frame. Slide the fuel tank's mounting tabs onto the frame's rubber bosses, then lower the tank onto the seat rails. Push the fuel hose onto the fuel tank valve. Screw the lower fuel tank mounting bolts into place, then tighten the bolts to 21.7 foot-pounds using a torque wrench.
Plug in the speedometer connectors to the bottom of the speedometer. Lay the speedometer bezel onto the fuel tank, then screw the speedometer bolts into place. Tighten the bolts to 7.6 foot-pounds.
Reinstall the rider and passenger seats.