8 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Parts catalogue
Caution
Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.
Removing the exhaust system
Caution
Before working on the exhaust system, ensure that the engine has been off for a certain time so that parts are cooled down.
 
Disconnect the rear turn indicators and number plate light wiring (Sect. P 1, Arrangement of wiring on frame).
Loosen the rubber clip (26) to separate the silencers (19) from exhaust pipe (11).
Loosen the special screw (17) and collect the washer (16).
Slide out the silencers (13) and (19) from rubber blocks (32) on the frame, together with tail guard heat shield (18) and number plate holder unit.
Please refer to Sect. H 7, Removing the number plate holder for number plate holder removal.
Loosen screws (17), and remove bracket (18), collect the washers (7) and separate silencers (13) and (19).
Loosen rubber clip (33) and separate the two silencers.
Remove circlips (A) from exhaust butterfly valve (B) motor cables assembly (12).
Remove cables (12) from exhaust butterfly valve (B).
Loosen screws (14) to remove the exhaust butterfly valve motor (9) from the frame and disconnect the wiring (C).
Disconnect the lambda sensor (20) from main wiring harness (Sect. P 1, Arrangement of wiring on frame).
See Sect. M 3 for details on the "Lambda sensor".
Loosen the clamp (26) and remove the tube (11).
To separate the presilencer (10) from vertical head exhaust pipe (2) and from horizontal head pipe (1), loosen clamps (27) and collect the gasket (28).
Unscrew the screw (25) securing presilencer (10) to frame.
Loosen nuts (3) and remove the exhaust manifold (2) from the vertical head and remove the horizontal head exhaust pipe (1) from the horizontal head, collect the gaskets (4).
Refitting the exhaust system
Change the seals (4).
Fit the horizontal head exhaust pipes (1) and vertical head exhaust pipes (2) with gaskets (4) onto the relevant heads and tighten nuts (3) to the specified torque (Sect. C 3, Frame torque settings).
Note
To improve sealing, it is recommended to smear some sealant on jointing area between presilencer (10) and vertical head exhaust pipe (2).
 
Position the presilencer (10) from below; fit the presilencer pipe into swingarm and hold it until it fits onto the vertical head exhaust pipe (2) with gasket.
Start the screw (25) in its thread, spacers (22) and nut (21) to secure presilencer (10) to bracket (24).
Tighten the nut (21) and tighten the screw (25) to the specified torque (Sect. C 3, Frame torque settings).
Fit pipes (1) and (2) with clamps (27), and gasket (8) onto presilencer (10).
Fit the clamp (27) for pipes (1) and (2) to presilencer (10), and set it so that the screw is parallel to the axis going through pipe notches (A). Fit clamp (27) ensuring that it is flush with pipe or in any case without completely uncovering notches (A).
Tighten the clamp (27) to the specified torque (Sect. C 3, Frame torque settings).
Connect the lambda sensor (20) to main wiring harness (Sect. P 1, Arrangement of wiring on frame).
Fit the tube (11) and the clamp (26) on presilencer (10).
Assemble exhaust butterfly valve motor (9) to rear subframe and tighten the screws (14) to the specified torque (Set. C 3, Frame torque settings).
Connect the motor to wiring (C).
If cables (12) have been removed from the motor, set them so that the top of motor pulley (in-between cables nipples) corresponds to the relevant notch. For easier assembly of the wires, use the instrument panel function that allows you to move the motor (Sect. P 7, Exhaust Butterfly Valve Motor Movement for wires installation).
Fit cables (12) onto exhaust butterfly valve motor (9).
Exhaust butterfly valve pulley limit stop (D) must rest on exhaust butterfly valve plate (B).
Fasten cables with the two circlips (A).
To correctly position the cables (12) please refer to the diagrams at the end of this section.
Cables must have no play.
Work adjusters (E) to adjust cables.
Position silencers (13) and (19), sliding them onto vehicle rear end, fitting them into pipe (11) and fitting silencer pins into rubber blocks (14) on the frame.
Fit washer (16) and start the screw (17) in its thread, tighten to the specified torque (Sect. C 3, Frame torque settings).
Connect the rear wiring (B) to the main wiring harness.