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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
34
35
36
 Parts catalogue
 Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the exhaust system
 
 Important
Before starting any work on the exhaust system, make sure that the engine has cooled down sufficiently.
 
Disconnect the turn signal and number plate light wiring connectors (Sect. P 1, Routing of wiring on frame).
Unscrew the hose clamp (7) to separate the silencers (19) from the exhaust pipe (11).
Unscrew the special bolt (17).
Withdraw the silencers (13) and (19), complete with undertail heat shield (18) and number plate holder assembly from the rubber mountings (32) on the frame.
Remove the splashguard (34), unscrewing the bolts (31) and recovering washers (26), (16) and bushes (36).
To separate the silencers (13) and (19) unscrew the bolts (34) and remove the bracket (30).
Unscrew the bolts (8) and remove the bracket (18).
Undo the clamp (33) and separate the two silencers.
Disconnect the lambda sensors (20) from the main wiring harness (Sect. P 1, Routing of wiring on frame).
 
For the “Lambda sensor” refer to Section M 3.
Remove the spring (9) and remove the pipe (11) from the presilencer (10).
Unscrew the clamp (27) to separate the presilencer (10) from the vertical cylinder exhaust pipe (2): recover the gasket (28).
Unscrew the bolts (25) and the nuts (21) securing the presilencer (10) to the frame.
Recover the bracket (24) and the support (1).
Unscrew the nuts (3) and remove the exhaust manifold (2) from the vertical cylinder head and the balance pipe (10) from the horizontal cylinder head, recovering the gaskets (4).
Refitting the exhaust system
Renew the gaskets (4).
Position the balance pipe (10) and vertical head exhaust pipe (2) with the gaskets (4) on their respective cylinder heads and tighten the nuts (3) to the specified torque (Sect. C 3, Frame torque settings).
Position the presilencer (10) from the underside of the motorcycle; insert the presilencer pipe in the swingarm.
Fit the bolts (25), the spacers (22), the support (1) and the nuts (21) to fix the presilencer (10) to the bracket (24).
Tighten the nuts (21) and (25) to the specified torque (Sect. C 3, Frame torque settings).
Connect the pipe (2) with the clamp (27) and gasket (28) to the presilencer (10).
Position the clamp (27) securing the pipe (2) to presilencer (10) so that the screw lies parallel to the line through the notches (A) in the end of the pipe. Position the clamp (27) so that it is flush with the end of the pipe, or at least so that the notches (A) are not completely uncovered.
Tighten the clamp (27) to the specified torque (Sect. C 3, Frame torque settings).
Connect the lambda sensors (20) to the main wiring harness (Sect. P 1, Routing of wiring on frame).
Position the hose (11) on the presilencer (10) with the spring (9).
Join the two silencers (13) and (19) tightening the clamp (33) ato the specified torque (Sect. C 3, Frame torque settings), securing the bracket (18) with the bolts (8) and tightening the bolts (8) to the specified torque (Sect. C 3, Frame torque settings).
Secure the silencer bracket (39) with bolts (34) tightened to the specified torque (Sect. C 3, Frame torque settings).
Fit the washers (16) on the bushes (36). Insert the rear end of the splashguard in the vibration damper (12), routing the wiring through the apertures in the spashguard.
Locate the bushes (36) so they rest against the clips (29). Insert the rubber vibration dampers (35) in the bushes (36). Fit the washers (26) on the bolts (31) and insert the bolts in the clips (29).
Tighten the bolts (31) to the specified torque (Sect. C 3, Frame torque settings).
Secure the wiring in the clips on the splashguard and bind them together with small tie.
Fit the silencers (13) and (19), inserting them from the rear of the motorcycle, connecting them to pipe (11) and inserting the pins of the silencer in rubber mountings (32) on the frame.
Tighten the bolt (17) to the specified torque (Sect. C 3, Frame torque settings).
Tighten the clamp (7) to the specified torque (Sect. C 3, Frame torque settings).
Reconnect the rear turn signal and number plate light wiring (Sect. P 1, Routing of wiring on frame).