2, FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION 24 SIDE FAIRING 23 | TROUBLESHOOTING 24 FUEL TANK 24 SIDE COVER 22 UPPER FAIRING 24 SEAT 2.2 REAR FENDER A 23 [2 TAIL COWL 23 REAR FENDER B 29 |_ MAINTENANCE COVER 23 EXHAUST SYSTEM 2-10 SERVICE INFORMATION GENERAL ‘xtremely flammable and is explosive under certain conditions. KEEP OUT OF REACH CHILDREN, ‘Serious bums may result if the exhaust system is not allowed to cool before components are removed or serviced, * Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion. * This section covers removal and installation of the frame body panels, fuel tank and exhaust system. + Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine. * When instelling the exhaust pipe, instell the exhaust system and all fastenets loosely. Always tighton the exhaust lamps first, then tighten the mounting fasteners. you tighten the mounting fasteners firs, the exhaust pipe may not oat properly, * Always inspect the exhaust system for | sfter installation. TORQUE VALUES Exhaust pipe joint nut 20 Nem (2.0 kg-m, 14 lb-ft) Exhaust pipe band bolt 21 Nem (2.1 kg-m, 15 Ib-ft) ‘Muffler mounting bolt 27 Nerm (2.7 kg-m, 20 Ib-A) Footpeg holder bolt 27 Nem (2.7 kg-m, 20 Ib-ft) Upper fairing stay bolt 27 Nem (2.7 kg-m, 20 lb-ft) TROUBLESHOOTING Excessive exhaust noi * Broken exhaust system + Exhaust gas leak Poor performance * Deformed exhaust system + Exhaust gas leak + Clogged muffior 2-1FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER REMOVAL Unlock the quick release fastonors by sligning the long slot with the punch mark. CAUTION careful not to break the pins, tabe and slots in the 1d tail cowl when removing the side cover. Remove the side cover by releasing the 3 bosses on the ‘cover from the grommets and carefully pulling the cover free from the tabe and pin in the back. INSTALLATION Install the side cover aligning its bosses with the grommets land engage the tabs with the slots, end pins with the hole securely as shown, Lock the clip by aligning the Do the same on the other side. \* mark with the punch mark SEAT REMOVAL/INSTALLATION Romove the side covers. Remove the seat by removing the 2 bolts and sliding the seat back. Install the seat in the reverse order of removal, the install the side covers. ve (2) UNLOCKED ee (9) LOCKE (2) BOSSES 2-2FRAME/BODY PANELS/EXHAUST SYSTEM TAIL COWL REMOVAL/INSTALLATION Remove the seat page 2-2). Remove the 2 bolts and tho tail cow! (one boss). Install the tail cowl in the reverse order of romoval.. MAINTENANCE COVER REMOVAL/INSTALLATION Remove the two screws and remove the maintenance cover backward. Install the maintenance cover in the reverse order of re- moval. NoTe wt {Align the tebs of the maintenance cover with the gro0vee of the upper end side faring securely SIDE FAIRING REMOVAL/INSTALLATION Remove the maintenance cover (page 2-3) and side cover (page 22). ‘ Turn the quick fastener counterclockwise and loosen it. Remove the bottom screw frorn the inner cover. Release the trim clips by pulling the center pin, Remove the seven bolts. Release the tabs from upper feiring and remove the side fair- ing Installation is in the revorso ordor of removal: Inctall the bolt with the high shoulder as shown. (2) TAIL COWL, (3) B0ss (a screws} (2) MAINTENANCE COVER (5) 8OLT WITH HIGH SHOULDER, 7 (QUICK FASTENER (3) BOTTOM SCREWi FRAME/BODY PANELS/EXHAUST SYSTEM (2) BOLTS/COLLARS FUEL TANK REMOVAL/INSTALLATION der certain conditions. KEEP OUT OF REACH OF CHIL- DREN. Remove the seat (page 2-2) Turn the fuel valve OFF. Remove the 6 mm bolt and collar. Remove the 8 mm bolt and collar. Lift the fuel tank up, Disconnect the fue! tube, breather tube and drain tube from ‘the fuel tank, thon romove the fuol tank. Installation is in the reverse order of removal. Before installing the ful tank, make sure the breather tube ‘and drain tube are through the guide es shown. After installation, turn the fuel valve ON and check the fuel line for leakage UPPER FAIRING REMOVAL, Romove the screws and rearview mirror inner coversFRAME/BODY PANELS/EXHAUST SYSTEM Remove the ytarviow mirror pivot boot. (Bouts (2) 80075 Remove the following: Bolts Rearview mirror Seat rubbor plato Seat rubber Remove the upper fairing lower cover (page 18-5). Remove the screws and air guides. Remove the upper fairing mounting bolts. Remove the screw and fuse box cover (page18-18). Slightly open both sides of the upper fairing rear ends, then pul the felring forward. Disconnect the turn signal connectors. Roloase the retaining tabs and remove the headlight socket, Remove the upper fairing assembly and windscreen.FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws and headlight. Remove the screws and disassemble the upper fairing. Pull out the turn signal wire from the wire guide groove. Remove the tur signal unit mounting nut and setting plate, Romove the sorews and inner cowl. Assembly is in the reverse order of disassembly. ay NuTINSTALLATION Install the windscreen, Connect the turn signal connectors and headlight socket. Install the upper fairing, aligning its bosses with the grom- mots. Engage the windseraen tabe with tho upper fairing slots so- curely as showin. Install the upper fairing assembly and windscreen, Install the upper fairing mounting bolts. Install the screw and fuse box cover (pege 18-18). Instell the air guides and screws, Install the upper fairing lower cover (page 18-5). FRAME/BODY PANELS/EXHAUST SYSTEM (2) BOSSES/GROMMETS} (1) TABS/SLOTSFRAME/BODY PANELS/EXHAUST SYSTEM Install the left seat rubber with the mark *MT4-L" facing out Install the left seat rubber plate with the marked side in and (SEAT AUBBEF each arrow mark pointing forward and down, (2) RUBBER PLATE T (3) ARROW MARKS Install the right seat rubber with the mark "MT4-" facing out a Install the right saat rubber plate with the marked side out | (1) SEAT RUBBER ‘and each arrow mark pointing forward and down, A (3) RUBBER PLATE (2) ARROW MARKS Install the rearview mirror and tighten the bolts, (1) Botts: Install the rearview mirror pivot boot, Install the rearvieyr mirror inner covers aligning its tabs with the slots. Insrail and tighten the screws.Se REAR FENDER A «ncownecrons eerrece REMOVAL/INSTALLATION Remove tho tail cow! (page 2-3) Disconnect the turn signel, brokostail light and license light connectors. Remove the bolts, nuts and rear fendor A. Installation isin the reverse order of removal. NoTE ‘At turn signal unit and licence light unit installation, route the wires as shown. _| REAR FENDER B REMOVAL/INSTALLATION Remove the side cover (page 2-2). Remove the bolts and left reer footpeg holder. Romove the bolts, nut and laft reflector. Remove the screws. (3) SCREWSIa Release the rear brake hose from clamps on rear fender B. oym(1) CLAMPS Romove the screws.FRAME/BODY PANELS/EXHAUST SYSTEM. Remove the reer fender B backward to the lef. Installation is in the reverse order of removel. Torque: Rear footpeg holder bolt: 27 Nem (2.7 kg-m, 20 tb-ft) NOTE [+ After clamping the brake hose with rear clamp on the | ‘ear fender B, make sure the olamp opening is less than 7 mm (0.28 in|. EXHAUST SYSTEM = + Do not service the exhaust eyetem whi MUFFLER REMOVAL/INSTALLATION Remove the side fairing (page 2-3). Loosen the two exhaust pipe band bolts. Remove the muffier mounting bolt, nut and muffler. Remove the mutfier packing Muffler installation is in the reverse order of removal bolt: 27 Nem 27 kg-m, 20 tb-ft) Exhaust pipe band bolt: 21 Nem (2.1 kg-m, 15 lb-ft) 2 the muffler packing with @ new ons EXHAUST PIPE REMOVAL/INSTALLATION Remove the upper fairing (page 2-4). CAUTION Be careful not to damage the radiator fins. Remove the radiator mounting bolte and release the grom ‘met on the radiator top from the bracket boss. Move the radiator forward and secure it (page 8-5). Remove the muffler. Romove the exhaust pipe joint nuts, Romove the exhaust pipe mounting bolt, nut, exhaust pipe and gaskets. (2) CLAMP} Oo “col LESS THAN Zmen (0.28 in) (3) MUFFLER ((1) BAND BOLTS y (2) BOLT/NUT (1) WASHER i (2) FLANGE COLLAR (2) MUFFLER (Nuts 2-10FRAME/BODY PANELS/EXHAUST SYSTEM Exhaust pipe installation is in the reverse order of removal. NoTE = Tighten all exhaust pipe joint nuts and clamp bolts loosaly. Always tighten the exhaust pipe joint nuts first, then the clamp bolt. ighten the joint nuts in order as shown, 20 Nem (2.0 kg-m, 14 1b-ft) Exhaust pipe band bolt: 21 Nem (2.1 kg-m, 16 lb-ft)