Sorry to grave dig, but I have searched everywhere and can't find the answer. I have also lost my only key to an 03 Kawi 636.well i was getting sick of not riding the bike so i took the electric ignition housing, zipties it to the orrig key slot(i took it out and sent it to the lock smith) and use a screw sriver to turn it on. As far as the key goes this is the process.
FIRST remove the gas tank. and loosen/remove all fairings on the left front. You will also have to remove the right side plastic peice just under the handle bars(i dont know whats its called).