Frame/Body Panels/Exhaust System

8/14/2019 Frame/Body Panels/Exhaust System

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RAME/BODY PANELS/EXHAUST SYSTEM

EATREMOVAL

Remove the tw o seat mount ing bolts behind the seat.

Slide the seat back and then off.Remove the mount ing collars.

INSTALLATI 0 N

Install the collars into the seat bot tom plate as shown.Alig n the seat hook with the fuel tank rear bracket andinstall t he seat.Install and tighten the bolts securely.

ILLION SEAT/REAR COWLREMOVAL

Remove the seat (see above).

Open the pillion seat using the ignition key.

Remove the p illi on seat mou ntin g nuts, then remove

the seat belt and pill ion seat.

Disconnect the seat lock cable from the key cylinder.

BOLTS

COLLARS

\

PILLION SEAT k I G N I , T I Y KEY

NUTS

I SEAT LOCK CABLE

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FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the tw o trim clips.Remo ve th e screws, special screws, setti ng bolts, COI-lars and spacers.Push down the pillion seat mounting bracket andcarefully spread the bottom of both sides of the rearcowl, then remove it fr om the seat rail.

Disconnect the tail light connector.

SETTING BOLT SCREWS

INSTALLATION1.5 N - m (0.15 kgfom, 1.1 IbfW

PILLION

BRA'CKET

SPECIAL -SCREWS

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FRAME BODY PANELS/EXHAUST SYSTEM

DUCT

Connect the tai l ligh t connector.Install the rear cowl over the seat rail being careful no tto damage the wire harness.

Install the spacers, setting collars and setting bolts.Install the special screws and truss screws.Install the tr im clips.

Tighten the setting bolts and special screws securely.

Tighten the screws to the specified torque.

TORQUE:Rear cowl truss screw:

1.5 N*m (0.15 kgf-m, 1.1 Ibf-ft)

Connect the seat lock cable to the key cylinder.

Install the pillion seat and nuts to the pillion seatbracket.

Tighten the nuts to th e specified torque.

TORQUE: 11 N-m (1.1 kgf-m, 8 Ibf-ft)

Push the pillion seat d ow n to lock it.

COVERREMOVAL/INSTALLATION

Remove the screws.Release the tab of the duct cover from the fuel tank,then remo ve the duct cover.

Installation is in the reverse order of re moval.

TORQUE: 1.5 N-m (0.15 kgfem, 1.1 Ibf*ft)

SETTING BOLT SCREWS

I COLLAR

BR A CKE TVSPECIAL SCREWS

NUTS

SEAT LOCK CABLE

SCREWS

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UPPER COWL BOLTSh

REMOVAL

Remove the duct cover (page 2-41.

Remove the socket bolts an d rearview mirrors.

Disconnect the turn signal light connectors.

Remove the nuts, set plates and turn signal lightsfrom the inner midd le cowl.

Remove the trim clips.Remove the windscreen -to -upper c owl bracket screws.Remove the upper cowl -to -lower cowl screws.

Remove the upper c owl mounting screws.

Pull the upper c owl forward.Disconnect the headlight connectors, then remo ve theupper cowl.


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FRAME/BODY PANELSIEXHAUST SYSTEM

INSTALL AT10 N

TURN SI GNAL LIGHT

Connect the headlight connectors to the headlightsockets o n the upper cowl.

Install the upper cowl onto the upper cowl stay whil e

aligning the headlight unit bosses wi th the upper cowlstay grommets.

Install the removed parts in the reverse order ofremoval.

TORQUE:Upper cowl pan screw (upper cowl -to -lower cowl):

Windscreen mounting screw (windscreen -to -uppercowl bracket):

GROMMETS

1.5 N-m (0.15 kgf-m, 1.1 lbf-ft)

0.3 N-m (0.03 kgf-m, 0.22 Ibf-ft)

HEADLIGHT CONNECTORS

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OWER COWLREMOVAL/INSTALLATION

Remove the tri m clip fro m the inner middle cowl.Remove the four tr im clips from the lower cowl.Remove the upper cowl -to -lower co wl screws.Remove the lower co wl mo unting screw, special boltsand then remove the lower cowl.

Installation is in the reverse order of removal.

TORQUE:Lowe r cowl pan screw:

1.5 N-m (0.15 kgf-m, 1.1 Ib fW

1.5 N- m (0.15 kgf-m, 1.1 Ibf-ft) TRIM CLIP

NNER

TURNS I ~ N A L

LIGHT

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FRAMEIBODY PANELS/EXHAUST SYSTEM

WINDSCREENREMOVAL/INSTALLATION

Remove the r ea rv iew mirrors (page 2-5).

Remove the screws, nylon washers and rubberwashers.Remove the windscreen by pulling out the setting

nuts from th e upper c owl bracket.

Windscreen mounting fasteners are plastic screws. Do not overtighten the screws.

Tighten the screws in

numerical order as shown in ?h e

illustration

Installation is in the reverse order of removal.

TORQUE: 0. 3 N* m (0.03kgf-m, 0.22 bfW

FRONT FENDERREMOVAL

Remove the brake hose clamp mountin g nuts.Remove the front fender mounti ng special bolts andref Iecto rs.

SCREWS(5 X 15)

WINDSCREEN

I

SCREW(5 x 20)

CLAM P NUT FRONT FENDER

1 REFLECTOR SPECIAL BOLTS

Remove the front fender b y pulling it forward.

INSTALLATION

Installation is i n the reverse order of removal.


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EAR FENDER

REAR FENDER A REMOVAL/INSTALLATION

Remove the rear co wl (page 2-2).

Disconnect the turn signal light connectors andlicense light connector.Remove the nuts, set plates and turn signal li ghts.Remove the nut and reflector, then remove reafender A.

Installation is i n the reverse order of removal.

CON N ECTORS

REAR FENDER REMOVAL

Remove the following:- Rear co wl (page 2-2)- Battery (page 16-4)- ECM (page 5-87)

Unhook the retaining tab and remove the fuse box.Remove the starter relay switch and fuel cut -off relayfr om the rear fender.

Disconnect the alternator 3P (Whi te) connector andregulator/rectifier 6P (Natu ral) connector.

I f i ~(NATURA L) CONNECTOR

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RAME/BODY PANELS/EXHAUST SYSTEM

Disconnect the turn signal connectors and license 1light connector.

I CON NE ~ T O R S

Remove the hea dlight relay, engine stop relay and fancontrol relay from the rear fender.

Remove the reflector m ount ing nut.Remove the two rear fender mounting bolts andcollars.

Unhook the rear fender fro m the seat rail brace, t henrelease th e regulatorirectifier wire and main wire har -ness f ro m the seat rail a nd rear fender.

Remove the rear fender by pulling it backward.

I HEADLIGHT RELAY FAN CONTROL RELAY

I ENGINE STOP RELAY

J NU T

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REAR FENDER INSTALLATION

CONNECTORSI I

F U S E B O X

ECM

Install the rear fender aligning its lower groove withthe seat r ail brace.

Connect the license light connector and turn signalconnectors.

Install the removed parts i n the reverse order ofremoval.

AT RAIL

REMOVAL

Remove the rear fender (Page 2-9).

Remove the muffler mount ing bol thut .Remove the socket bolts and right pillionbracket.

footpeg

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Remove the socket bolts and left pilli onbracket.

Remove the bolts and regulator/rectifier.

footpeg

Remove the fuel tank rear bracket bolts.Remove the seat rail mlounting 8 mm bolts, 10 mmbolts/nuts and seat rail.

INSTALL AT1 0 N39 N * m (4.0 kgf-m, 29 Ibf-ft)

39 N - m

REG ULATORIRECTI FIE R

39 N-rn (4.0 kgf-m, 29 Ibf-ft)PILLION FOOTPEGBRACKET

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FRAMEIBODY PAN ELS/EXHAUST SYSTEM

Install the seat rail and tighten the moun tingnuts to the specified torque.

TORQUE:8 m m bolt: 39 N.m (4.0 kgf-m, 29 Ibf-ft)10 m m nut: 39 N- m (4.0 gf-m, 29 I b f W

bolls am d

Install the regulator/rectifier, tighten th e bolts.

Install the left pillion footpeg bracket and tighten thesocket bolts t o the specified torque.

TORQUE: 39 N- m (4.0 kgfmm, 29 Ibf-ft)

Install the right p illion footpeg bracket and tighte n thesocket bolts t o the specified torque.

TORQUE: 39 N*m (4.0 kgf-m, 29 Ibf*ft)

Install the m uffler mount ing bolt, washer an d nut, andtigh ten the n ut securely.

Install the removed parts in the reverse order ofremoval.

MUFFLER/EXHAUST PIPEREMOVAL

Do not service the exhaust system whi le it is hot.

Remove the lower co wl (page 2-71.

Remove the exhaust pipe -to -muffler joint nuts.Remove the muffler mounting bol t /nut and washer,then remove the muffler.

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Remove the gasket.

Caiifornia typeonly

Disconnect the 0 2 sensor 4P (Natural) connector.Remove the 0 2 sensor wire f rom the frame.

RAME/BOQY PANELS/EXHAUST SYSTEM

I

he 0 2 sensor wire fro m the right step guard.

Caiifornia :ypeonly

Remove the 0 2 sensor wire clamp.Remove the righ t step guard mounting bolts and col -lars.

Caiifornia type Rele

on iy,

se

14 p (NATURAL) CONNECTOR

~

CLAMP COLLARS

10 2 SENSOR WIRE RIGHT STEP GUARD

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Remove the tw o bolts and EGCV (Exhaust Gas ControlValve) p ulle y cover.

Disconnect the EGCV control cables fro m t he pulley. I CONTROL CABLES

Remove the exhaust pipe joint nuts.

Remove the followin g:- Exhaust pipe mou nting bolt/nut- Washer- Collar- Exhaust pipe- Exhaust pipe gaskets

See page 5-97 for EGCV removal id isassembly.

PULLEY

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INSTALLATION

Non-California type:

-1 12 N-m (1.2 kaf-m, 9 b f W

EXHAUST PIPE LSSEMBLY 12 N* m (1.2 'kgf*rn, 9 Ibf-ft)

California type:

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Install the exhaust pipe mounting rubber and collarinto the lowe r bracket hole.

Check the protrusion of the exhaust pipe stud bolt(page 1-14).

Aiways repiacee exhaustpipe

kets with ne w ones

Install the ne w exhaust pipe gaskets onto th e exhaustports of the cylinder head.

Install the exhaust pipe, and temporarily install theexhaust pipe joint nuts and mounting b o l t h u t .


Temporarily tighten the exhaust pipe mo unt ing nut.

COLLARIMOU NTING RU BB


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Connect the EGCV control cables to th e cable pulley. CONTROL CABLESn

Caiifornia type o n k

Clamp the 02 sensor wire to the right step guard.

I PULLEY

Install the EGCV pulley cover and tigh tenthe specified torque.

TORQUE: 12 N-m (1.2 kgfsm, 9 Ibf-ft)

the bolts to

Caiifornia type only

Install the rear master cylinder, collars and right stepguard, then tighten the mounting bolts.Clamp the 0 2 sensor wire wi th the rear brake reservoirhose using the hose clamp.


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Caiifornia typeonly

Route the 0 2 sensor wire into the frame.Connect the 0 2 sensor 4P (Natural) connector.

Install the new gasket onto the exhaust pipe asshown.

Install the muffler.

Temporarily install the m uffle r mounting bolt/nut an dmuffler joint nuts.

irst tighten ?he

nuts

Tighten all of the muffleriexhaust pipe mountinghaust pipe ~ o i n t bolts/nuts securely.

TORQUE:Exhaust pipe joint nut: 12 N-m (1.2 kgf-m, 9 Ibf-ft)

Install the lower cow l (page 2-7 )

Frame/Body Panels/Exhaust System

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