Lay out the pieces in order of removal.....
Just a note to myself (and anyone else wanting to save time) to remember to lay out the pieces or at least draw a diagram of what is removed and in the proper order, with their screws. You will save time putting it back together and not have too many screws left over like I did.
The removal, replacement and twisting of the plastic to get everything interlocked, to me, is more difficult on the K1600GTL, then my previous 02 K1200LT. I took the task for granted and definitely regretted it.
Thinking that It would not be a problem, and after all, I took my previous K1200LT apart numerous time over th years and rarely had a screw left over, I disassembled my K1600GTL to install a horn and had a bear of a time getting her back together and replacing all of the screws.
It's nice that most of the screws on the K1600GTL, holding on the plastic, are the same size, except for the two on the #6 plate, but many are really hidden. There are a few with special washers too, but if I had done a better job of laying out the pieces and kept the screws with each piece, it would not have taken 6 hours to add a new horn.
There are a lot of areas where it does seem simpler to disassemble the K1600GTL, like around the top, But the many of the side pieces interconnect and having them in the proper order eliminates multiple removals to get to hidden screws.
12 K1600 GTL
02 K1200 LT (gone but not forgotten)