2. Vehicle Body, Muffler
Overhaul Info…………………… ….………….2-1
Troubleshooting……….….……….……………..2-1
Front Rack, Bolt Cap………………………….…2-2
Seat, Seat Support & Rear Rack……………….2-3
Front & Rear Rack Panels, Front Top Cover….2-4
Rear Top Cover……………………..…………....2-5
Left Side Panel…………………………………...2-6
Right Side Panel……………………………….…2-7
Fuel Tank Top Cover, Front Fender…………....2-8
Footrest Board (LH, RH)………………………...2-9
Rear Fender, Engine Skid Plate (Front, Center, Rear),
Double Seat, Protection Plate……………………………..2-10
Front Inner Fender (RH,LH), Front Protector (RH, LH)…2-12
Rear Protector (RH,LH), Bumper, Bumper Protector……2-13
Bumper Cap…………………………………..……………..2-14
Front Vent Grille, Fuel Tank…………………….………….2-15
Bottom Plate, Fuel Tank…………………………………….2-16
Muffler……………………………………….………………..2-17
Description of Visible Parts………….…………………..…2-18
Overhaul Information
Operation Cautions
Warning
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.
Special attention should also be paid to sparks. Gasoline may also be explosive when it is
vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
z This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe, muffler and fuel
tank.
z Hoses, cables and wiring should be routed properly.
z Replace the gasket with a new one after muffler is removed.
z After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Muffler Rear Fixing Bolt: 35-45N.m
Muffler Exhaust Pipe Bolt: 35-45N.m
Muffler Body Fixing Bolt: 35-45N.m
Troubleshooting
Loud exhaust noise
z Broken muffler
z Exhaust leakage
Insufficient power
z Distorted muffler
z Exhaust leakage
z Muffler clogged
2-1
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