2.
. FRAME COVERS/EXHAUST MUFFLER SERVICE INFORMATION...................... 2-1 FRAME COVERS......................................2-2 TROUBLESHOOTING ............................ 2-1 EXHAUST MUFFLER REMOVAL ........2-6 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
2. FRAME COVERS/EXHAUST MUFFLER FRAME COVERS Bolts REAR HAND GRIP REMOVAL Remove the six bolts attaching the rear hand grip. Remove the rear hand grip. The installation sequence is the reverse of removal. FRAME REAR COVER REMOVAL Disconnect the third stoplight wire connector. Remove the frame rear cover. The installation sequence is the reverse of removal.
2. FRAME COVERS/EXHAUST MUFFLER Remove the fuel tank cap. Remove the two seat attaching bolts and the seat. Remove the two bolts and two nuts attaching the met-in box. Remove the met-in box. The installation sequence is the reverse of removal. Remove the two screws inside the frame body cover on the joint between the floor board and the frame body cover. Disconnect the seat lock wire. Remove the frame body cover. FRAME CENTER COVER REMOVAL Remove the two screws on the bottom of the frame center cover.
2. FRAME COVERS/EXHAUST MUFFLER FRONT COVER REMOVAL Remove the bolt on the front of the front cover. Remove the twelve screws that combine the front cover with the front tool box. Remove the front cover and disconnect the headlight wire connector. The installation sequence is the reverse of removal. Front Cover Screws Bolt Handlebar Front Cover Screws Back Cover Handlebar Rear Cover HANDLEBAR FRONT/REAR COVER REMOVAL HANDLEBAR FRONT COVER REM OVAL Remove the right and left rearview mirrors.
2. FRAME COVERS/EXHAUST MUFFLER FLOOR BOARD REMOVAL Remove the battery cover. Remove the battery cables. Remove the battery. Remove the CDI unit. CDI Unit ＊• When removing, first disconnect the battery negative (-) cable and then the positive (+) cable. • When installing, first connect the positive (+) cable and then the negative (-) cable. Battery Bolts Remove the rear right and left side covers. (!2-2) Remove the frame body cover. (!2-2) Remove the front right and left side covers.
2. FRAME COVERS/EXHAUST MUFFLER EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts to remove the exhaust muffler. Remove the exhaust muffler joint packing collar. When installing, first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler. Torques: Exhaust muffler lock bolt: 3.5kg-m Exhaust muffler joint lock nut: 1.2kg-m ＊ Be sure to install a new exhaust muffler packing collar.
