FRAME/BODY PANELS/EXHAUST SYSTEM. SERVICE INFORMATION GENERAL Work in a well ventilated aree. Smoking or allowing flames or sparks in the work area or where gesoline & stored cam cause @ fire or explosion. This section covers removal and installation of the body panels, fuel tank and exhaust system, Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. ‘When installing the exhaust system, loosely install all of the exhaust pipe fasteners first. Always tighten the ewes pipe joint nuts first, then tighten the mounting fasteners. If you tighten the mounting fasteners first. the exmoust Sime may not seat properly Always inspect the exhaust system for leeks after instalation. TORQUE VALUES Exhaust pipe joint nut 20 Nem (2.0 kgfom, 14 IBF) Exhaust pipe protector mounting bolt 14 Nem (1.4 kgfem, 10 IDF) Muffler mounting bolt 26 N-m (2.7 kgf-m, 20 tft) Muff band bolt 20 Nem (2.0 kgf-m, 14 IDF) Spark arrester mounting bolt 1a.Nem (14 kghm, 10 Ibt-A) TROUBLESHOOTING Excessive exhaust noise + Broken exhaust system © Exhaust gas leak Poor performance + Deformed exhaust system + Exhaust gas leak * Clogged muffler 2-2FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Remove the nuts, collars and bolts. Slide the seat backward and remove it. INSTALLATION Align the hook of the seat with the mounting boss on the fuel tank. Also align the seat prong with the frame tab. Install the bolts, collars and nuts, then tighten the nuts securely. SIDE COVERS REMOVAL/INSTALLATION Remove the screws. Remove the side covers by pulling out the bosses from the grommets. GROMMETS BOSSES Install the side covers in the reverse order of removal. BOSSES GROMMETSFRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the bolts, washers and front fender. Installation is in the reverse ordar of removal. REAR FENDER REMOVAL/INSTALLATION Remove the seat (page 2-3) and side covers (page 2- 3). BOLTSWASHERS Remove the bolts, washers and rear fender. Installation isin the reverse order of removal. NUMBER PLATE REMOVAL/INSTALLATION Remove the number plate tab from the handlebar. Remove the bolt, collar and number plate. Install the number plate by aligning its rubber | ‘mounts with the front fender mounting bolts on the | steering stem, | Install the collar and tighten the bolt securely. |FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK REMOVAL/INSTALLATION Remove the seat (page 2-3). Disconnect the breather hose from the steering stem nut. Turn the fuel valve OFF, and disconnect the fuel hose. Unhook the mounting strap. Remove the two mounting bolts/washers and the fuel tank from the frame. Installation is in the reverse order of removal. BREATHER HOSE FUEL TANK STRAP BOLT/WASHER BOLT/WASHER SS FUEL VALVE COLLARS FUEL HOSE SKID PLATE REMOVAL/INSTALLATION Remove the bolt/collar and two bolts, then remove the skid plate. Installation is in the reverse order of removal. SKID PLATEFRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER Refer to page 3-21 for spark arrester cleaning, REMOVAL, Remove the right side cover (page 2.3). ' Loosen the muffler band bolt. MUFFLER BAND BOLT Remove the muffler mounting bolts and muffler. sets ataremoving the exhaust pve i | Always reptce the Remove the exhaust pipe joint nuts and exhaust oxnaustpipo 92e- pipe. from tha engin 2-6FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION 14 N-m (1.4 kgf-m, 10 Ibf-ft) 26 Nem = GASKET EXHAUST PIPE JOINT NUTS 20 N-m (2.0 kgf-m, 14 Ibf-ft) 14 N-m (1.4 kgf-m, 10 Ibf-ft) EXHAUST PIPE Install the new exhaust pipe gasket onto the exhaust ! port of the cylinder head. you tighten the Loosely install all of the exhaust pipe and muffler mounting bolts fasteners. first, the exhaust pive may not seat properly. Tighten the exhaust pipe joint nuts to the specified | torque. i TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft) 2-7FRAME/BODY PANELS/EXHAUST SYSTEM. Tighten the muffler band bolt to the specified torque, TORQUE: 20 N-m (2.0 kfm, 14 Itt) MUFFLER BAND BOLT Tighten the muffler mounting bolt (front) and nut (rear) to the specified torque. Sou TORQUE: 26 N-m (2.7 kgfm, 20 IbF-ft) After installation, inspect the exhaust system for leaks. 2-8