BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY

Remove the following:

– Turn signal light mounting nuts and turn signal lights

– Bolts and turn signal light stay

– Screws and license light assembly

– Grommet

– Nuts and number plate bracket (CM type)

Assemble is in the reverse order of disassembly.

EXCEPT CM TYPE:

GROMMET

REAR TURN

SIGNAL LIGHT

LICENSE LIGHT ASSEMBLY

CM TYPE:

SCREW

BOLT

8.8 N·m (0.9 kgf·m, 6.5 lbf·ft)

STAY

EXHAUST PIPE/MUFFLER

REMOVAL

Remove the lower cowl (page 2-8).

Remove the exhaust pipe joint nuts.

NUT

NUMBER PLATE BRACKET

JOINT NUTS

2-13

BODY PANELS/EXHAUST SYSTEM

Remove the muffler mounting bolt, collar, rubber and nut.

BOLT/COLLAR/

RUBBER/NUT

Remove the exhaust pipe mounting bolt, nut, washer, collar and rubbers.

Remove the exhaust pipe/muffler as assembly.

Remove the exhaust pipe gasket.

BOLT/NUT/WASHER/

COLLAR/RUBBERS

GASKET

2-14

MUFFLER

DISASSEMBLY/ASSEMBLY

Remove the following:

– Bolts, spring washers, washers and exhaust pipe cover

– Bolts, nuts and muffler guard

– Bolts, muffler and gasket

Assembly is in the reverse order of disassembly.

Always replace the muffler gasket with a new one whenever the muffler is removed from the exhaust pipe.

TORQUE:

Muffler joint bolt:

13 N·m (1.3 kgf·m, 10 lbf·ft)

Exhaust pipe cover bolt:

13 N·m (1.3 kgf·m, 10 lbf·ft)

BODY PANELS/EXHAUST SYSTEM

GASKET

13 N·m (1.3 kgf·m, 10 lbf·ft)

COVER

MUFFLER GUARD

13 N·m (1.3 kgf·m, 10 lbf·ft)

EXHAUST PIPE

2-15

BODY PANELS/EXHAUST SYSTEM

INSTALLATION

NUT

COLLAR

RUBBER

GASKET

RUBBERS

WASHER

MUFFLER MOUNTING BOLT

EXHAUST PIPE MOUNTING BOLT WASHER

Install a new exhaust pipe gasket to the exhaust port of the cylinder head.

Always replace the exhaust pipe gasket with a new one whenever the exhaust pipe is removed.

Install the exhaust pipe/muffler, then temporarily install the all mounting fasteners.

NUT

COLLAR

EXHAUST PIPE/

MUFFLER

EXHAUST PIPE

JOINT NUTS

GASKET

Tighten the exhaust pipe joint nuts securely.

JOINT NUTS

2-16

Tighten the exhaust pipe mounting bolt and nut securely.

BODY PANELS/EXHAUST SYSTEM

Tighten the muffler mounting bolt and nut securely.

After the installation, inspect the exhaust system for leaks.

BOLT/NUT/WASHER/

COLLAR/RUBBERS

MUFFLER MOUNTING BOLT/NUT

STUD BOLT REPLACEMENT

Remove the exhaust pipe/muffler (page 2-13).

Thread two nuts onto the stud and tighten them together, and use a wrench on them to turn the stud bolt out.

Install new stud bolts into the cylinder head until it is fully seated as shown.

Install the exhaust pipe/muffler (page 2-16).

Fully seated

2-17

MEMO

3. MAINTENANCE

3

SERVICE INFORMATION ··························· 3-2

MAINTENANCE SCHEDULES···················· 3-4

FUEL LINE ··················································· 3-6

THROTTLE OPERATION····························· 3-7

AIR CLEANER·············································· 3-8

CRANKCASE BREATHER ··························· 3-9

SPARK PLUG ·············································· 3-9

VALVE CLEARANCE································· 3-11

ENGINE OIL··············································· 3-13

ENGINE OIL STRAINER SCREEN ············ 3-14

RADIATOR COOLANT ······························ 3-15

COOLING SYSTEM··································· 3-15

DRIVE CHAIN············································ 3-16

BRAKE FLUID ··········································· 3-21

BRAKE PADS WEAR ································ 3-22

BRAKE SYSTEM ······································· 3-23

BRAKE LIGHT SWITCH ···························· 3-23

CLUTCH SYSTEM ···································· 3-24

HEADLIGHT AIM ······································ 3-24

SIDESTAND ·············································· 3-25

SUSPENSION ··········································· 3-25

NUTS, BOLTS, FASTENERS···················· 3-26

WHEELS/TIRES ········································ 3-26

STEERING HEAD BEARINGS ·················· 3-27

3-1