Chasis,. Paneles y Exosto CBF

FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
• 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 fasteners, tighten the exhaust pipe joint nuts first, tighten the
muffler band bolt, then tighten the muffler mounting bolts.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Exhaust pipe stud bolt 11 N·m (1.1 kgf·m, 8 lbf·ft) See page 2-10
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-2
FRONT COWL
REMOVAL/INSTALLATION
Remove the front cowl mounting screws and bolt.
Remove the front cowl and disconnect the head- FRONT
light/turn signal light 6P (Black) connector. COWL SCREWS
Remove the bolts and number stay from the front
cowl.
Installation is in the reverse order of removal.
STAY
6P CONNECTOR
BOLTS
BOLT
WIND SCREEN
Remove the front cowl (page 2-3).
SCREWS
Do not damage the Remove the screws and wind screen.
wind screen.
WIND
SCREEN
SEAT
Insert the ignition key into the seat lock and turn it
clockwise. SEAT
Pull the seat lock lever downward.
Slide and remove the seat to the backward.
Install the seat, while aligning its hook with the
bracket on the frame.
Turn the ignition key counterclockwise and remove
the key.
LEVER
2-3
RIGHT SIDE COVER
Remove the seat (page 2-3).
Remove the right side cover mounting screws.
SCREW B
Be careful not to Release the side cover bosses from the fuel tank.
damage the side Remove the right side cover. SCREW A
cover bosses.
Installation is in the reverse order of removal. B
A
BOSSES
RIGHT SIDE COVER SCREW
LEFT SIDE COVER

Remove the left side cover mounting screws.
Be careful not to Release the side cover bosses from the fuel tank.
damage the side Remove the left side cover. LEFT SIDE A B
cover bosses. COVER
SCREW B
BOSSES SCREW A
SCREW
FUEL TANK
Remove the following:
FUEL VALVE
– left side cover (page 2-4)
– right side cover (page 2-4)
Wipe the spilled Turn the fuel valve "OFF" and disconnect the fuel
gasoline off at hose.
once.
FUEL HOSE
2-4
Remove the fuel tank mounting bolt and washer.
While raising the fuel tank disconnect the fuel unit FUEL TANK BOLT/WASHER
2P (Brown) connector.
Pull back and remove the fuel tank.
After installation, Installation is in the reverse order of removal.
turn the fuel valve
"ON" and make sure
that there are no
fuel leaks.
2P CONNECTOR
FRONT FENDER
Remove the front wheel (page 12-12).
– cable guide
– four bolts and brake hose clamp
– front fender and stay BRAKE HOSE
CLAMP
BOLTS
GUIDE
STAY
FRONT FENDER
2-5
REAR GRIP
BOLTS REAR GRIP
Remove the mounting bolts and rear grip.
REAR COWL
– right side cover (page 2-4)
– left side cover (page 2-4)
– rear grip (page 2-6)
Remove the two rear cowl mounting screws, bolt
and washer. BOLT
Raise the rear cowl assembly and disconnect the WASHER
brake/tail light 3P connector.
3P
Remove the rear cowl assembly. REAR COWL CONNECTOR
While installing the Installation is in the reverse order of removal. ASSEMBLY
rear cowl, route the
wire harness prop-
erly page 1-17.
SCREWS
2-6
DISASSEMBLY/ASSEMBLY
Remove the two screws and center rear cowl.
SCREWS CENTER REAR COWL
Remove the nuts, washers and brake/tail light unit.

Remove the screws and separate the right/left rear
cowl from the stay.
Assembly is in the reverse order of disassembly.
LEFT REAR
COWL
NUTS/
WASHERS
RIGHT REAR SCREWS

COWL
BRAKE/TAIL
LIGHT UNIT
2-7
REAR FENDER
Remove the rear cowl (page 2-6).
Disconnect the turn signal light wire connectors.
Remove the bolts, collars and rear fender.
While installing the Installation is in the reverse order of removal.
rear fender, route CONNECTORS
the wire harness
properly page 1-17.
REAR
FENDER
COLLARS BOLTS
SAREE GUARD
Remove the rear cowl (page 2-6).
Remove the mounting bolts and saree guard. SAREE
Installation is in the reverse order of removal. GUARD
BOLTS
2-8
EXHAUST PIPE/MUFFLER
REMOVAL
– exhaust pipe joint nuts
– muffler mounting bolt, washer and nut
– exhaust pipe/muffler
– gasket
MOUNTING WASHER
BOLT
GASKET
NUT
JOINT
EXHAUST PIPE/ NUTS
MUFFLER
INSTALLATION
Install a new gasket into the exhaust port.
Always replace the Install the exhaust pipe/muffler.
exhaust pipe gasket Loosely install the muffler mounting bolt, washer
with a new one and nut.
when remove the Install the exhaust pipe joint then install and tighten MOUNTING WASHER
exhaust pipe from the exhaust pipe joint nuts. BOLT
the engine. GASKET
Always inspect the Tighten the muffler mounting bolt.

exhaust system for
leaks after installa-
tion.
NUT
JOINT
EXHAUST PIPE/ NUTS
MUFFLER
2-9
DISASSEMBLY/ASSEMBLY
Remove the two bolts, muffler protector, collars and
rubber mounts.
Remove the two bolts, front cover, collar and rubber
mount.
BOLTS
Remove the rear cover from the muffler.
Assembly is in the reverse order of disassembly.
PROTECTOR
REAR COVER
FRONT
COVER
COLLAR/
RUBBER
MOUNT
STUD BOLT REPLACEMENT

Remove the exhaust pipe stud bolts from the cylin-
der head. 20.5 – 22.5 mm
(0.81 – 0.89 in)
Install a new stud bolts into the cylinder head
embed to incomplete threads.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)
After installing the stud bolts, check that the length
from the bolt head to the cylinder head surface is
within specification.
STUD BOLT
(Embed to incomplete thread)
2-10

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FRAME/BODY PANELS/EXHAUST SYSTEM

RIGHT SIDE COVER SCREW

LEFT SIDE COVER

Remove the nuts, washers and brake/tail light unit.

RIGHT REAR SCREWS

Always inspect the Tighten the muffler mounting bolt.

STUD BOLT REPLACEMENT

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