WARNING
The muffler can become extremely hot during normal operation and cause severe burns. Do not remove the muffler while it is hot.

Muffler Body Removal

• Remove:
Muffler Body Cover Bolts [A] and Collars
Front Muffler Body Cover [B]

the muffler body clamp bolt [A].
• Loosen
the muffler body mounting bolt [B], washer and
• Remove
nut.
out the muffler body [C] backward from the premuffler
• Pull
chamber.

5-38 ENGINE TOP END
Muffler
Muffler Body Installation

the muffler body gasket [A] with a new one.
• Replace
the muffler body gasket to the premuffler chamber
• Install
[B] so that the chamfer side faces premuffler chamber.
the muffler body clamp [C] as shown.
•○Install
Insert the projection [D] into the slot [E].
the muffler body [F].
• Install
Tighten
the muffler body mounting bolt [G] with the
• washer [H].
Torque - Muffler Body Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)

• Tighten the muffler body clamp bolt [I].
Torque - Muffler Body Clamp Bolt: 17 N·m (1.7 kgf·m, 13
ft·lb)

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

ENGINE TOP END 5-39
Muffler
that the pad [A] is in place on the front muffler body
• Check
cover [B].
• Install:
Dampers [C]

•

Collars [D]
Front Muffler Body Cover
Rear Muffler Body Cover [E]
Tighten the muffler body cover bolts [F].

Premuffler Chamber Removal

• Remove:
Muffler Body (see Muffler Body Removal)
•

Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Remove the lower ends of the exhaust butterfly valve cables from the pulley of the premuffler chamber (see Exhaust Butterfly Valve Cable Removal).

the exhaust pipe clamp bolt [A].
• Loosen
Remove
• washer. the premuffler chamber mounting bolt [B] and
out the premuffler chamber [C] backward from the
• Pull
exhaust pipe.

5-40 ENGINE TOP END
Muffler
Premuffler Chamber Installation

the premuffler chamber gasket [A] with a new
• Replace
one.
the premuffler chamber gasket to the premuffler
• Install
chamber [B] until it is bottomed so that the chamfer side
faces exhaust pipe [C].
Install the exhaust pipe clamp [D] as shown.
○Insert the projection [E] into the slot [F].
Install the premuffler chamber.
Tighten the premuffler chamber mounting bolt [G] with the
washer [H].

•
•
•

Torque - Premuffler Chamber Mounting Bolt: 34 N·m (3.5
kgf·m, 25 ft·lb)

• Tighten the exhaust pipe clamp bolt [I].
Torque - Exhaust Pipe Clamp Bolt: 17 N·m (1.7 kgf·m, 13
ft·lb)

the removed parts (see appropriate chapters).
• Install
Thoroughly
up the engine, wait until the engine
• cools down, warm
retighten all the bolts.

Exhaust Pipe Removal

• Remove:
Radiator (see Radiator and Radiator Fan Removal in the
•

Cooling System chapter)
Oxygen Sensor [A] (see Oxygen Sensor Removal in the
Electrical System chapter)
Loosen the exhaust pipe clamp bolt [B].

ENGINE TOP END 5-41
Muffler
the exhaust pipe holder nuts [A], and pull out the
• Remove
exhaust pipe [B] forward from the premuffler chamber.

5-42 ENGINE TOP END
Muffler
Exhaust Pipe Installation

the exhaust pipe gaskets [A] and premuffler
• Replace
chamber gasket [B] with new ones.
the premuffler chamber gasket to the premuffler
• Install
chamber [C] until it is bottomed so that the chamfer side
faces exhaust pipe [D].
Install the exhaust pipe clamp [E] as shown.
○Insert the projection [F] into the slot [G].
Install the exhaust pipe.
Tighten the exhaust pipe holder nuts [H] following the
tightening sequence [1  8].
Right Side [I]
Left Side [J]

•
•
•

Torque - Exhaust Pipe Holder Nuts: 20 N·m (2.0 kgf·m, 15
ft·lb)

○Confirm that the flange face [K] does not touch the flange

•

face [L] of the engine side.
Viewed from under [M]
Tighten the exhaust pipe clamp bolt [N].
Torque - Exhaust Pipe Clamp Bolt: 17 N·m (1.7 kgf·m, 13
ft·lb)

the removed parts (see appropriate chapters).
• Install
Thoroughly
up the engine, wait until the engine
• cools down, warm
retighten all the bolts and nuts.

ENGINE TOP END 5-43
Muffler
Exhaust Butterfly Valve Cable Removal

the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
• Slide the dust covers [A].

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

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

• Remove:
Front Muffler Body Cover (see Muffler Body Removal)
Exhaust Butterfly Valve Pulley Cover Bolt [A]
Exhaust Butterfly Valve Pulley Cover [B]

the locknuts [A].
• Loosen
the lower ends [B] of the exhaust butterfly valve
• Remove
cables from the pulley.
• Pull the exhaust butterfly valve cables out of the frame.

5-44 ENGINE TOP END
Muffler
Exhaust Butterfly Valve Cable Installation

installing the exhaust butterfly valve cables, con• Before
firm that the exhaust valve actuator pulley [A] is in the
original position as shown.

○The pulley edge [B] and housing screw [C] are on the
same line. This position is original position of the pulley.
If the pulley is not in the original position, adjust it (see
Exhaust Butterfly Valve Actuator Adjustment).

NOTICE
Do not attempt to move the pulley by hand or using
a tool as internal actuator damage will occur.
the close cable (black) [A], and then install the open
• Install
cable (silver) [B] to the exhaust valve actuator pulley.
• Install the clamp [C].

the exhaust butterfly valve cables to the muffler
• Install
body as shown (see Cable, Wire, and Hose Routing sec-

•
•

tion in the Appendix chapter).
Close Cable (Black) [A]
Open Cable (Silver) [B]
Upside [C]
Tighten the exhaust butterfly valve cable locknuts.
Install the exhaust butterfly valve pulley cover, and tighten
it bolt.

the open cable (silver) first. Loosen the locknut [A]
• Adjust
and turn the adjuster [B] until there is no play in the cable.
the open cable locknut.
• Tighten
Adjust
the
close cable (black). Loosen the locknut [C] and
• turn the adjuster
[D] until there is no play in the cable.
Turn
the
adjuster
of the close cable clockwise by 1/2 to 1
• rotation.
• Tighten the close cable locknut.

NOTICE
To keep the correct exhaust butterfly valve position,
adjust the open cable first. Adjust the cables only
until there is no play. If the cables are adjusted any
further, the exhaust butterfly valve actuator will not
operate correctly.

• Install the removed parts (see appropriate chapters).

ENGINE TOP END 5-45
Muffler
adjusting the cables, turn the ignition switch on and
• After
make sure that the pulley turns clockwise, then counterclockwise and then returns slightly clockwise as shown.

NOTE

○The stop position [A] of the pulley is changed by the
cables tension and the closed position of the exhaust
butterfly valve.
If the pulley does not move smoothly, adjust the cables
again.

Exhaust Butterfly Valve Actuator Removal
NOTICE
Never drop the exhaust butterfly valve actuator especially on a hard surface. Such a shock to the actuator can damage it.

• Remove:
Exhaust Butterfly Valve Cables (see Exhaust Butterfly
•

Valve Cable Removal)
Fuse Boxes
Disconnect the exhaust butterfly valve actuator lead connectors [A].

• Remove:
Exhaust Butterfly Valve Actuator Mounting Screws [A]
and Collars
Clamp [B]
Exhaust Butterfly Valve Actuator [C]

5-46 ENGINE TOP END
Muffler
removing the pulley, note the following.
• When
Remove
the pulley bolt while holding the pulley [A] with
• the suitable
tool [B].

NOTICE
If the pulley bolt is removed without holding, the
actuator damage will occur.

• Remove the pulley from the actuator.
Exhaust Butterfly Valve Actuator Installation

installing the pulley, note the following.
• When
the pulley [A] on the actuator so that the holes side
• Install
[B] aligns with the groove [C].

the pulley bolt [A] while holding the pulley [B] with
• Tighten
the suitable tool [C].
Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 5.0
N·m (0.51 kgf·m, 44 in·lb)

NOTICE
If the pulley bolt is tightened without holding, the
actuator damage will occur.

• Install:
Exhaust Butterfly Valve Actuator
Exhaust Butterfly Valve Actuator Mounting Screws and
Collars
Clamp
Torque - Exhaust Butterfly Valve Actuator Mounting
Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)

the exhaust butterfly valve cables (see Exhaust
• Install
Butterfly Valve Cable Installation).

ENGINE TOP END 5-47
Muffler
Exhaust Butterfly Valve Actuator Adjustment
Pulley Position Electrically Adjustment
Turn the ignition switch off.
Disconnect the exhaust butterfly valve actuator lead connectors.
Connect the exhaust butterfly valve actuator connector (2
pins) to the battery to turn the pulley as follows.
Connection for counterclockwise [A]
Connection for clockwise [B]
Adjust the pulley position until it returns to the original
position.

•
•
•
•

that the exhaust valve actuator pulley [A] is in the
• Confirm
original position as shown.

○The pulley edge [B] and housing screw [C] are on the
same line. This position is original position of the pulley.

CLUTCH 6-1

Clutch
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tool and Sealant ........................................................................................................
Clutch Lever and Cable ..........................................................................................................
Clutch Lever Free Play Inspection ....................................................................................
Clutch Lever Free Play Adjustment ..................................................................................
Clutch Cable Removal ......................................................................................................
Clutch Cable Installation ...................................................................................................
Clutch Cable Lubrication...................................................................................................
Clutch Lever Assembly Installation ...................................................................................
Clutch Lever Removal.......................................................................................................
Clutch Lever Installation....................................................................................................
Clutch Cover...........................................................................................................................
Clutch Cover Removal ......................................................................................................
Clutch Cover Installation ...................................................................................................
Release Shaft Removal ....................................................................................................
Release Shaft Installation .................................................................................................
Clutch Cover Disassembly................................................................................................
Clutch Cover Assembly.....................................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Spring Plate Free Play Measurement ...............................................................................
Spring Plate Free Play Adjustment ...................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp Inspection............................................................................................
Clutch Spring Inspection ...................................................................................................
Clutch Housing Finger Inspection .....................................................................................
Clutch Housing Spline Inspection .....................................................................................
Damper Cam Inspection ...................................................................................................

6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-9
6-9
6-9
6-10
6-10
6-10
6-11
6-12
6-12
6-13
6-16
6-17
6-18
6-18
6-18
6-19
6-19
6-19

6

6-2 CLUTCH
Exploded View

CLUTCH 6-3
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Clutch Lever Clamp Bolts
Clutch Cover Bolts
Oil Filler Plug
Clutch Spring Bolts
Sub Clutch Hub Bolts
Clutch Cover Plate Bolts
Clutch Hub Nut

CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease.

N·m
9.0
10
–
11
25
10
130

Torque
kgf·m
0.92
1.0
–
1.1
2.5
1.0
13.3

ft·lb
80 in·lb
89 in·lb
–
97 in·lb
18
89 in·lb
95.9

Remarks
S
S
Hand-tighten
L
L
R

6-4 CLUTCH
Specifications
Item
Clutch Lever and Cable
Clutch Lever Free Play
Clutch
Spring Plate Free Play
Clutch Plate Assembly Length
Friction Plate Thickness
Friction and Steel Plate Warp

Standard
2  3 mm (0.08  0.12 in.)
(Usable Range)
0.05  0.70 mm (0.002  0.028 in.)
(Reference)
53.5 mm (2.11 in.)
2.72  2.88 mm (0.107  0.113 in.)
0.15 mm (0.0059 in.) or less

Service Limit
– – –

– – –
– – –
2.6 mm (0.10 in.)
0.3 mm (0.012 in.)

CLUTCH 6-5
Special Tool and Sealant
Clutch Holder:
57001-1243

Liquid Gasket, TB1211F:
92104-0004

6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection

to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.

Clutch Lever Free Play Adjustment

to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.

Clutch Cable Removal

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
•

in the Fuel System (DFI) chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Loosen the nuts [A], and slide the lower end of the clutch
cable to give the cable plenty of play.

in the adjuster [A].
• Screw
Line
up
[B] in the clutch lever and adjuster, and
• then freethetheslots
cable from the lever.
Free
the
clutch
inner cable tip from the clutch release
• lever.
• Remove the clutch cable.

Clutch Cable Installation

the clutch cable correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
the clutch cable (see Clutch Operation Inspection
• Adjust
in the Periodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).

Clutch Cable Lubrication

to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.