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2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION························ 2-2 DRIVE SPROCKET COVER····················· 2-7

TROUBLESHOOTING ···························· 2-2 DRIVE CHAIN COVER···························· 2-7

BODY PANEL LOCATIONS····················· 2-3 FUEL TANK UNDER TRAY ····················· 2-8

PASSENGER SEAT (CM model) ·············· 2-4 FUEL TANK UNDER COVER··················· 2-9

SINGLE SEAT ······································· 2-4 BATTERY CASE ································· 2-11

SIDE COVER ········································ 2-4 SIDESTAND ······································· 2-11

REARVIEW MIRROR······························ 2-5 MUFFLER ·········································· 2-12

FRONT FENDER ··································· 2-5 EXHAUST PIPE··································· 2-13

REAR FENDER ····································· 2-6

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FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM

GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Always replace the exhaust pipe gasket with new ones after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust pipe joint nuts
first, then tighten the mounting bolts.
• Always inspect the exhaust system for leaks after installation.

TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler

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FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS

CM model shown:
(4)
(10)

(2) (1) (6)

(5)

(9) (7) (3) (11) (8)

(12)

(1) Passenger Seat (CM model) (6) Rear Fender (page 2-6) (11) Battery case (page 2-11)
(page 2-4)
(2) Single Seat (page 2-4) (7) Drive Sprocket Cover (page 2-7) (12) ABS Modulator Cover (CMX500A)
(page 19-24)
(3) Side Cover (page 2-4) (8) Drive Chain Cover (page 2-7)
(4) Rearview Mirror (page 2-5) (9) Fuel tank under tray (page 2-8)
(5) Front Fender (page 2-5) (10) Fuel tank under cover (page 2-9)
• This chart shows removal order of frame covers by means of arrow.

(2) Single Seat (9) Fuel tank under tray

(6) Rear Fender (10) Fuel tank under cover

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FRAME/BODY PANELS/EXHAUST SYSTEM

PASSENGER SEAT (CM model)
REMOVAL/INSTALLATION
Remove the mounting bolt [1] and collar [2].
Remove the passenger seat [3] by pulling it frontward. [3]
[5]
Install the passenger seat by inserting the boss [4] into
the seat retainer [5]. [1]
Install and tighten the mounting bolt securely.
• Replace the passenger seat mounting bolt with a
new one.

[2]
[4]

SINGLE SEAT
REMOVAL/INSTALLATION
Remove the mounting socket bolts [1] and collars [2].
Remove the single seat [3] by pulling it rearward. [1]
[3]
Install the single seat by inserting its hook [4] into the
seat bracket [5] under the fuel tank.
Install and tighten the mounting socket bolts securely.
[4]

[2]

[5]

SIDE COVER
REMOVAL/INSTALLATION
Release the bosses [1].
Right side shown:
Remove the side cover [2].
Install the side cover in the reverse order of removal.

[1]
[2]

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FRAME/BODY PANELS/EXHAUST SYSTEM

REARVIEW MIRROR
REMOVAL/INSTALLATION
Slide the boot [1] off from the lock nut [2].
Left side shown: [3]
Loosen the lock nut (left-hand threads) and remove the
rearview mirror [3].
Remove the mirror adaptor [4]. [1]
Installation is in the reverse order of removal.
[2]
TORQUE:
Rearview mirror adapter/lock nut
19 N·m (1.9 kgf·m, 14 lbf·ft)

[4]

FRONT FENDER
REMOVAL/INSTALLATION
Remove the front wheel (page 16-10).
Remove the self-lock nuts [1], washers [2], collars [3] and reflectors [4].
Remove the bolts [5], hose guide [6], collars [7], fender stay [8] and front fender [9] from the fork legs.
Install the front fender in the reverse order of removal.
TORQUE:
Front reflector mounting nut:
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
• Replace the fender mounting bolts with a new one.

[6]

[7]

[9]

[3]

[8]

[4]
[5] [1] [2]

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FRAME/BODY PANELS/EXHAUST SYSTEM

REAR FENDER
REMOVAL/INSTALLATION
Remove the single seat (page 2-4).
Disconnect the following connectors [1] in the connector boot:
– turn signal 2P (Light blue)
– turn signal 2P (Orange)
– brake/taillight 3P
Remove the following:
– two bolt/washers [2]
– regulator/rectifier stay [3]
– two socket bolts (right side) [4]
– passenger footpeg bracket (right side) [5]
– two socket bolts (left side) (CM model) [6]
– passenger footpeg bracket (left side) (CM model) [7]
– four bolts [8]
– rear fender [9]
Install the front fender in the reverse order of removal.
TORQUE:
Seat rail mounting bolt:
54 N·m (5.5 kgf·m, 40 lbf·ft)
passenger footpeg bracket socket bolt:
33 N·m (3.4 kgf·m, 24 lbf·ft)

CM model shown:

[8]

[2]

[3]

[4]

[9]

[1]

[5] [7]

[6]

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FRAME/BODY PANELS/EXHAUST SYSTEM

DRIVE SPROCKET COVER
REMOVAL/INSTALLATION
Remove the following:
– pinch bolt [1]
– gearshift arm [2]
– band clip (lower side) [3] [8]
– two bolts [4]
– band clip (front side) [5] Align
– drive sprocket cover [6] [7]
– drive chain guide [7]
Installation is in the reverse order of removal.
[1]

• Temporarily hang the chain guide on the water [9]

pump lug and drive chain, and then install the drive
sprocket cover with the upper bolt to set the chain [2]
guide and sprocket cover properly.
• Route the sidestand switch wire [8] into the guide [9] [5]
in the sprocket cover.
• Align the slit in the gearshift arm with the punch
mark on the spindle.

TORQUE:
Drive sprocket cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

[4]
[3] [6]

DRIVE CHAIN COVER

REMOVAL/INSTALLATION
Remove the bolts [1], trim clip [2] and drive chain cover
[3]
[3]. [1]
Install the drive chain cover in the reverse order of
removal.

[1]

[2]

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FRAME/BODY PANELS/EXHAUST SYSTEM

FUEL TANK UNDER TRAY
REMOVAL/INSTALLATION
Remove the following:
Right side:
– fuel tank (page 7-9)
– ignition switch stay (page 21-14)
– ECM (page 4-31)
– four trim clips [1]

[1]

Left side:

[1]

No.2 spark plug Remove the trim clips [1].

wire only. [2]
Disconnect the spark plug caps [2].

[1]

Remove the two bolts [1].

Remove the following and release the PAIR control [5]/[6] [4] [3]
solenoid valve [2] from the stay.
– nut [3]
– collar [4]
– washer [5]
– socket bolts [6]

[2]

[1]

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FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the following: [2]
[1]
– turn signal/hazard relay [1] [3]
– fan control relay [2]
– main relay [3] [4]
– fuel pump relay [4]
– turn signal/hazard diode [5]
[5]
– wire junction [6]
– fuel tank under tray [7]

[6]

[7]

Disconnect the ignition coil connectors [1].

[1]
Installation is in the reverse order of removal.
TORQUE:
PAIR control solenoid valve nut:
8.5 N·m (0.9 kgf·m, 6.3 lbf·ft)
[1]

FUEL TANK UNDER COVER

REMOVAL/INSTALLATION
Remove the fuel tank under tray (page 2-8).
Disconnect the throttle cables [1] (remove from the [1]
cable holder and disconnect from the throttle drum).

Disconnect the clutch cable [1] (remove from the cable

[1]
holder and disconnect from the clutch lifter arm).

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FRAME/BODY PANELS/EXHAUST SYSTEM

Remove the bolts [1], trim clips [2] and center cover [3].
[1] [2]

[3]

Remove the trim clip [1]. [1] [4]

Release the main wire harness [2] from wire stay [3]. [3]
Remove the left fuel tank under cover [4].

[2]

Remove the trim clip [1].

[1] [2]
Remove the right fuel tank under cover [2].
Release the clutch cable [3] and throttle cables [4] off of
the cable guide.
Installation is in the reverse order of removal.
TORQUE:
Throttle cable adjuster lock nut [4]
(throttle body side):
3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)
Adjust the following:
– throttle grip freeplay (page 3-4) [3]
– clutch lever freeplay (page 3-21)

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FRAME/BODY PANELS/EXHAUST SYSTEM

BATTERY CASE
REMOVAL/INSTALLATION
Remove the following:
– rear wheel (page 17-5) [5]
– battery (page 20-5)
– reservoir mounting bolt [1]
– reservoir cover [2]
– brake hose stay [3]
– reservoir [4]
– two bolt/washers [5] [6]
– regulator/rectifier stay [6]
– fuse box [7]
– two bolts [8]
– two special bolts [9]
Release the negative (–) cable [10] off of the cable
guide. [9]
[10]
Release the grooves [11] and boss [12]. [7]
Remove the battery case [13].
Installation is in the reverse order of removal.
[11]

[4]

[8]

[12] [1] [2] [3]

[13]

SIDESTAND
REMOVAL/INSTALLATION
Remove the sidestand switch from the sidestand pivot
(page 21-17).
[4]
Retract the sidestand and remove the following: [3]
– spring [1]
– pivot nut [2] and bolt [3]
– sidestand [4]
Installation is in the reverse order of removal.

• Apply grease to the pivot area.

• After tightening the pivot bolt to the specified torque,
turn it 45 – 90 ° counterclockwise.
• When tightening the pivot nut, hold the pivot bolt
[2] [1]
securely.
• The spring is installed in the direction as shown.

TORQUE:
Pivot bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Pivot nut: 30 N·m (3.1 kgf·m, 22 lbf·ft)

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FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER
REMOVAL/INSTALLATION
Loosen the muffler band bolt [1].
[2]
Remove the following:
– nut [2]
– bolt [3]
– washer [4]
– muffler [5] [4]
– collar [6]
– gasket [7]
Be sure that the muffler band tab is aligned with the
muffler groove in position. [3]
Install a new gasket and the collar.
Install the muffler with the washer, bolt and nut, and
loosely tighten it.
Tighten the muffler band bolt first, then tighten the
mounting nut to the specified torque.
TORQUE:
Muffler band bolt: 22.5 N·m (2.3 kgf·m, 17 lbf·ft)
[5] [6] [7]
[1]

Align

[1]

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DISASSEMBLY/ASSEMBLY
Disassemble and assemble the muffler components as shown in the following illustration.

MUFFLER COVER RUBBER

SOCKET BOLT
SETTING RUBBERS
(Install with the ribs facing out)

MUFFLER

EXHAUST PIPE
REMOVAL/INSTALLATION
Disconnect the O2 sensor 4P (Black) connector and
remove the O2 sensor wire out of the frame (page 4-35).
Remove the following:
– muffler (page 2-12)
– four joint nuts [1] [6]
– mounting bolt [2]
– exhaust pipe [3]
– collar [4]
– mounting rubbers [5]
– gaskets [6]
Be sure to verify the length from the stud bolt head to [5]
the cylinder head surface (page 2-14).
Install new gaskets and the collar.
Install the exhaust pipe with the mounting bolt and joint
nuts by setting the exhaust pipe flanges onto the stud
bolts, and screw all the fasteners in fully. [2] [4]
Tighten the joint nuts first to the specified torque, then
tighten the mounting bolt.
TORQUE:
Exhaust pipe joint nut: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Install the removed parts in the reverse order of
removal. [1]
[3]

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FRAME/BODY PANELS/EXHAUST SYSTEM

STUD BOLT REPLACEMENT
Remove the exhaust pipe (page 2-13).
Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud bolt
out.
Install new stud bolts into the cylinder head as shown.
After installing the stud bolts, check that the length from
the bolt head to the cylinder head surface is within
specification.
Install the exhaust pipe (page 2-13).

19.5 – 20.5 mm
(0.77 – 0.81 in)

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