Disassembly/assembly (left side only)

 

Remove the screws [1] and separate the side lower cover [2] from the left side cover [3] by releasing its slots [4] and holes [5] from the hooks and bosses of the side cover.

 

Assembly is in the reverse order of disassembly.

 

TORQUE:

 

Left side cover assembly screw: 0.9 N·m (0.1 kgf·m, 0.7 lbf·ft)

 

Align

 

 

[3]

 

[4]

 

[1] [2] (Right side only)

 

 

[1]

 

[5]

 

[3]	[4]	[2]

 

2-3

FRAME/BODY PANELS/EXHAUST SYSTEM

 

RESERVE TANK COVER

 

REMOVAL/INSTALLATION

 

Remove the trim clips [1], socket bolt [2] and reserve tank cover [3].

Installation is in the reverse order of removal.

 

• Align the cover boss [4] with the hole [5] of the stay.

 

[3]

[1]

 

[5]

 

[4]

 

[2]

 

FUEL TANK SHROUD

 

REMOVAL/INSTALLATION

 

Right side only: Remove the reserve tank cover (page 2-4).Remove the side cover (page 2-3).

 

Remove the socket bolt A [1], socket bolts B [2] and fuel tank shroud [3].

 

Installation is in the reverse order of removal.

 

DISASSEMBLY/ASSEMBLY

 

Right side: Remove the four screws [1] and separate the grille [2]and front shroud [3] from the rear shroud [4] by releasing its tabs [5] and boss [6] from the slots and hole of the rear shroud.

 

Left side: Remove the two screws [1] and separate the frontshroud [3] from the rear shroud [4] by releasing its tabs [5] and boss [6] from the slots and hole of the rear shroud.

 

Assembly is in the reverse order of disassembly.

 

TORQUE:

 

Fuel tank shroud assembly screw: 0.9 N·m (0.1 kgf·m, 0.7 lbf·ft)

 

 

[1]

 

[3]

 

 

[2]

[2] (Right

[1] (Right

side only)

side only)

[5]

[4]

[1]

[3]

[6]

 

2-4

FRAME/BODY PANELS/EXHAUST SYSTEM

 

SKID PLATE

 

REMOVAL/INSTALLATION

 

Remove the two bolts [1] and skid plate [2]. Installation is in the reverse order of removal.

• Align the rear side of the skid plate with the frame slot [3].

 

 

HEADLIGHT COWL

 

REMOVAL/INSTALLATION

 

[3]

 

[1]

 

[2]

 

Remove the four bolt/washers [1] and headlight cowl [2].

Disconnect the headlight 3P (Black) connector [3] and position light 2P (Black) connector [4].

 

Installation is in the reverse order of removal.

 

TORQUE:

 

Headlight cowl mounting bolt: 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft)

 

[2]

 

[3]

 

[4]

 

FRONT FENDER

 

REMOVAL/INSTALLATION

 

Remove the four bolt/washers [1], front fender [2] and collars [3]

Installation is in the reverse order of removal.

 

[1]

 

 

[3]

 

 

[2]

 

[1]

 

 

2-5

FRAME/BODY PANELS/EXHAUST SYSTEM

FRAME GUARD

 

REMOVAL/INSTALLATION

 

Remove the socket bolts [1] and frame guard [2].

[2]

Installation is in the reverse order of removal.

 

[1]

 

DRIVE SPROCKET COVER

 

REMOVAL/INSTALLATION

 

Remove the bolts [1] and drive sprocket cover [2].

[1]

Installation is in the reverse order of removal.

 

[2]

 

DRIVE CHAIN COVER (U TYPE ONLY)

 

REMOVAL/INSTALLATION

 

Remove the socket bolts [1] and drive chain cover [2]. Installation is in the reverse order of removal.

[2]

 

 

[1]

 

2-6

FRAME/BODY PANELS/EXHAUST SYSTEM

TOOL BOX

 

REMOVAL/INSTALLATION

 

Remove the following:

– Seat (page 2-3)

 

– Left side cover (page 2-3)

 

Remove the two mounting bolts [1] and tool box [2]. Installation is in the reverse order of removal.

 

 

		[2]
[1]

 

DISASSEMBLY/ASSEMBLY

 

Disassemble and assemble the tool box as following illustration.

HINGE

 

 

TOOL BOX

 

 

TOOL BOX COVER

 

 

SPECIAL WASHER

 

 

LOCK SPRING

 

 

LOCK UNIT

 

REAR FENDER

 

REMOVAL/INSTALLATION

 

Remove the bolts [1] and rear fender [2].

Installation is in the reverse order of removal.	[2]

 

 

[1]

 

2-7

FRAME/BODY PANELS/EXHAUST SYSTEM

DISASSEMBLY/ASSEMBLY (U TYPE

ONLY)

 

Remove the nuts [1], bolts [2], collars [3], license holder plate [4] and license plate stay [5].

 

Remove the stopper rubber [6].

 

Remove the nuts [7] and rear side reflectors [8]. Assembly is in the reverse order of disassembly.

 

TORQUE:

 

Rear side reflector mounting nut: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

^[2] [5]

[4]

 

 

[8]

 

[7]	[6]	[1]/[3]

 

REAR UPPER FENDER

 

REMOVAL/INSTALLATION

 

Remove the seat (page 2-3).
		[2]
[1]			[6]
Remove the hook bolts [1] and collars [2].
Slightly spread the side covers [3] and release the
bosses [4] and tabs [5].
Remove the rear upper fender [6].
Installation is in the reverse order of removal.
TORQUE:
Hook bolt: 21 N·m (2.1 kgf·m, 15 lbf·ft)
							[5]

 

[4]

[3]

 

TAIL COVER/LIGHT UNIT

 

REMOVAL/INSTALLATION
Remove the following:
			[2]
– Rear upper fender (page 2-8)
[1]
– Rear fender (page 2-7)
Disconnect the brake/taillight 6P (Black) connector [1].
		[3]

Remove the bolts A [2], bolts B [3] and tail cover/light unit [4].

 

Installation is in the reverse order of removal.

 

[4]

 

2-8

FRAME/BODY PANELS/EXHAUST SYSTEM

 

DISASSEMBLY/ASSEMBLY

 

Remove the following:

 

– Rear fender (page 2-7)

– Rear turn signal units (page 20-4)

 

Disassemble and assemble the tail cover/light unit as following illustration.

 

REFLECTOR

 

MOUNTING NUT

		1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
SOCKET BOLTS

 

RIGHT TAIL COVER

 

REAR REFLECTOR

 

BRAKE/TAILLIGHT UNIT

 

LEFT TAIL COVER

 

 

SCREW

 

 

BRAKE/TAILLIGHT MOUNTING SCREWS

 

4.5 N·m (0.5 kgf·m,

 

3.3 lbf·ft)

 

COLLARS

 

REAR TURN SIGNAL UNIT STAY

 

REAR LOWER FENDER

 

REMOVAL/INSTALLATION

 

Remove the following:

 

– Seat (page 2-3)

[1]

– Side covers (page 2-3)

– Tail cover/light unit (page 2-8)

 

Release the wire bands [1].

 

2-9