ENGINE TOP END 5-41

Muffler

•Install the muffler body (see Muffler Body Installation).

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

Exhaust Pipe Removal

•Remove:

Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter)

Oxygen Sensor (Equipped Models) (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter)

Exhaust Pipe Guard (see Premuffler Chamber Removal) Exhaust Pipe Clamp Bolt [A]

5-42 ENGINE TOP END

Muffler

•Remove the exhaust pipe holder nuts [A], and pull out the exhaust pipe forward from the premuffler chamber.

Exhaust Pipe Installation

•Replace the exhaust pipe gaskets [A] [B] with new ones.

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

About 4.0 mm (0.16 in.) [F]

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

Rear View [J]

•Install the exhaust pipe.

•Tighten:

Torque - Exhaust Pipe Holder Nuts [K]: 17 N·m (1.7 kgf·m, 13 ft·lb)

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

•Install the damper [M] to the exhaust pipe.

○Insert the projection [N] of the exhaust pipe into the hole [O] of the damper.

2 mm (0.08 in.) [P]

1 mm (0.04 in.) [Q]

ENGINE TOP END 5-43

Muffler

•Install the removed parts (see appropriate chapters).

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

Exhaust Butterfly Valve Cable 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].

5-44 ENGINE TOP END

Muffler

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

•Remove the clamp [A].

•Remove the upper ends [B] of the exhaust butterfly valve cables from the pulley [C].

•Remove the muffler body cover (see Muffler Body Removal).

•Loosen the locknuts [A].

•Remove the lower ends [B] of the exhaust butterfly valve cables from the pulley [C].

•Pull the exhaust butterfly valve cables out of the frame.

Exhaust Butterfly Valve Cable Installation

•Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±0.7° [B]

○This position is original position of the pulley.

NOTE

○Correct the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure.

CAUTION

Do not correct the pulley position with the tool, forcibly. The actuator damage will occur.

If the angle is wrong, adjust the pulley (see Exhaust Butterfly Valve Actuator Installation in the Fuel System (DFI) chapter).

ENGINE TOP END 5-45

Muffler

•Run the exhaust butterfly valve cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Install the lower ends of the exhaust butterfly valve cables to the pulley of the muffler body as shown in the figure.

Open Cable (White) [A]

Close Cable (Black) [B]

•Tighten:

Torque - Exhaust Butterfly Valve Cable Locknuts [C]: 7.0 N·m (0.71 kgf·m, 62 in·lb)

5-46 ENGINE TOP END

Muffler

•Install the upper ends of the exhaust butterfly valve cables to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence.

○First, install the close cable (black) [A]. ○Second, install the open cable (white) [B].

○Third, stretch the open cable (white) by using the adjuster [C].

○Turn the adjuster counterclockwise until the play of the open cable becomes no play.

CAUTION

To keep the correct exhaust butterfly valve position, be sure to adjust the open cable first. Do not overstretch the cable.

○Fourth, tighten the adjuster locknut (white) of the open cable securely.

Torque - Exhaust Butterfly Valve Cable Adjuster Locknuts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

○Fifth, stretch the close cable (black) by using the adjuster [D].

○Turn the adjuster counterclockwise until the play of the close cable becomes no play.

○Sixth, turn the adjuster of the close cable (black) clockwise by 1/2 to 1 rotation.

○Seventh, tighten the adjuster locknut (black) of the close cable securely.

Torque - Exhaust Butterfly Valve Cable Adjuster Locknuts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

•After installation, cover the dust covers on the adjusters as shown in the figure.

10 mm (0.39 in.) or less [E]

15 mm (0.59 in.) or less [F]

•Fix the exhaust butterfly valve cables with the clamps [G].