ENGINE TOP END 5-37

Muffler

WARNING

To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down.

Muffler Body Removal

•Remove the front seat (see Front Seat Removal in the Frame chapter).

•Open the clamp [A] and free the cables.

•Slide the dust covers [B].

•Loosen the locknuts [A], and turn the adjusters [B] to give the cable plenty of play.

•Remove: Bolts [A]

Muffler Body Rear Cover [B] Bolts [C]

Muffler Body Cover [D]

•Remove the lower ends of the exhaust butterfly valve cables from the pulley of the muffler body (see Exhaust Butterfly Valve Cable Removal).

•Loosen the muffler body clamp bolt [A].

•Remove the muffler body mounting bolt [B], and pull out the muffler body [C] backward from the premuffler chamber.

5-38 ENGINE TOP END

Muffler

Muffler Body Installation

•Replace the muffler body gasket [A] with a new one.

•Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side [C] faces muffler body [D].

About 4.0 mm (0.16 in.) [E]

•Install the muffler body clamp [F] as shown in the figure. ○Insert the projection [G] into the slot [H].

Rear View [I]

•Install the muffler body.

•Tighten:

Torque - Muffler Body Mounting Bolt [J]: 25 N·m (2.5 kgf·m, 18 ft·lb)

Muffler Body Clamp Bolt [K]: 17 N·m (1.7 kgf·m, 13 ft·lb)

•Install the lower ends of the exhaust butterfly valve cables, and adjust the cables correctly (see Exhaust Butterfly Valve Cable Installation).

•Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts.

ENGINE TOP END 5-39

Muffler

•Install the muffler body cover, and tighten the bolts.

Torque - Muffler Body Cover Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb)

•Install the damper [A] on the muffler body cover [B].

•Install the muffler body rear cover, and tighten the bolts.

Torque - Muffler Body Rear Cover Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb)

•Install the removed parts (see appropriate chapters).

Premuffler Chamber Removal

•Remove:

Muffler Body (see Muffler Body Removal) Guard Bolts [A]

Premuffler Chamber Guard [B]

•Remove:

Guard Bolts [A] Exhaust Pipe Guard [B]

•Loosen the exhaust pipe clamp bolt [A].

•Remove the bolts [B].

•Pull out the premuffler chamber backward from the exhaust pipe.

5-40 ENGINE TOP END

Muffler

Premuffler Chamber Installation

•Replace the exhaust pipe gasket [A] with a new one.

•Install the exhaust pipe gasket to the exhaust pipe [B] until it is bottomed so that the chamfer side [C] faces premuffler chamber [D].

About 4.0 mm (0.16 in.) [E]

•Install the exhaust pipe clamp [F] as shown in the figure. ○Insert the projection [G] into the slot [H].

Rear View [I]

•Install the premuffler chamber and bracket [J].

•Tighten:

Torque - Premuffler Chamber Mounting Bolt [K]: 35 N·m (3.6 kgf·m, 26 ft·lb)

Premuffler Chamber Bracket Bolt [L]: 35 N·m (3.6 kgf·m, 26 ft·lb)

Exhaust Pipe Clamp Bolt [M]: 17 N·m (1.7 kgf·m, 13 ft·lb)

•Install the exhaust pipe guard [N].

○Insert the projection [O] of the guard into the hole [P] of the damper [Q].

2 mm (0.08 in.) [R]

1 mm (0.04 in.) [S]

•Tighten:

Torque - Exhaust Pipe Guard Bolts [T]: 6.9 N·m (0.70 kgf·m, 61 in·lb)

•Install the premuffler chamber guard [U].

•Tighten:

Torque - Premuffler Chamber Guard Bolts [V]: 6.9 N·m (0.70 kgf·m, 61 in·lb)