2.

BODY PANELS/ EXHAUST SYSTEM

2
SAREE GUARD WIND SCREEN

FUEL TANK SHROUD

REAR COWL
REAR GRIP
SEAT

FRONT COWL

FRONT FENDER

REAR
FENDER

LEG GUARD
EXHAUST MUFFLER
SIDE COVER

2-0
BODY PANELS/ EXHAUST SYSTEM

Body Part Identification 2-0 Fuel Tank Shrouds 2-6

Service Information 2-1 Fuel Tank 2-6
Torque Values 2-1 Front Fender Cover 2-7
Troubleshooting 2-1 Front Fender 2-8
Seat/ Side Cover/ Rear Grip 2-2 Saree Guard/ Leg Guard 2-8
Rear Cowl 2-3 Exhaust Pipe/ Muffler 2-9
Front Cowl 2-4 Rear Fender 2-9

SERVICE INFORMATION
WARNING
Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced .

GENERAL
• This section covers removal and installation of the body panels and exhaust system. The body panels installation is in the
reverse order of removal, unless noted other wise.
• Always replace the exhaust pipe gaskets with new ones after loosening or removing the exhaust pipe joint nuts.
• When installing the exhaust system, loosely install all the exhaust pipe fasteners. Always tighten the exhaust mounting nuts from
the cylinder head side first, then tighten the other mounting fasteners. If you tighten the mounting bolt and nut first, the exhaust
pipe may not seat properly.
• Always inspect the exhaust system for leak after installation.

TORQUE VALUES

ENGINE HANGER PLATE NUT : 2.6 kgf-m

For other nuts, bolts, fasteners etc. refer to standard torque values (SECTION- 1).

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

2-1
 BODY PANELS/ EXHAUST SYSTEM
SEAT
SEAT
Insert the ignition key into the seat lock and unlock by turning
the key clockwise.
Remove the seat while releasing the hooks from the frame.

To install, engage the hook on the underside of the seat with

2
the frame and press on the top rear side of the seat until the
lock clicks.

KEY
GROMMET
SIDE COVERS
LEFT SIDE COVER
Remove the three screws from the left side cover.
Release the side cover lug from the grommet in the fuel tank
and remove the left side cover while releasing its tabs from the
rear cowl.

Installation is in the reverse order of removal.

SCREWS
SCREWS GROMMET
RIGHT SIDE COVER
Remove the three screws from the right side cover.
Release the side cover lug from the grommet in the fuel tank
and remove the right side cover while releasing its tabs from
the rear cowl.

Installation is in the reverse order of removal.

REAR GRIP
REAR GRIP
Remove the four mounting bolts.
Remove the rear grip.

Installation is in the reverse order of removal.

BOLTS

2-2
BODY PANELS/ EXHAUST SYSTEM
BOLTS
REAR COWL
Remove the seat and side covers (page2-2).
Remove the rear grip (page2-2).
Remove the rear cowl top mounting bolts.

Remove the cowl mounting bolt and screw from the right
side.

SCREW BOLT
SCREW
Remove the cowl mounting bolt and screw from the left side.

BOLT

Carefully slide the rear cowl assembly towards rear and

separate it from the frame.

REAR COWL

2-3
 BODY PANELS/ EXHAUST SYSTEM
SEAT LOCK CABLE SEAT LOCK CABLE END
The seat lock fitted on the left side of rear cowl is engaged
with the seat lock cable end.

Release the seat lock cable end from the key seat lock.
Install in the reverse order of installation.
2

SEAT LOCK

FRONT COWL
Remove the screw from the right panel.

SCREW

Remove the screw from the left panel.

SCREW
RIGHT PANEL
Remove the left and right panel from the front cowl.

LEFT PANEL

2-4
BODY PANELS/ EXHAUST SYSTEM
SCREW
Remove the screw and bolt from the left side of the front cowl.

BOLT
SCREW
Remove the screw and bolt from the right side of the front
cowl.

BOLT
FRONT COWL ASSEMBLY
Remove the front cowl assembly by carefully spreading the
front cowl and dislodging the boss from the front cowl stay.

Disconnect the front cowl connector from the main wiring

harness.

Installation is in the reverse order of removal.

HEADLAMP CONNECTOR

2-5
 BODY PANELS/ EXHAUST SYSTEM
SCREWS
FUEL TANK SHROUDS
REMOVAL
Remove three fuel tank shroud mounting screws from both
sides.
2

FUEL TANK SHROUD

LUG
Slide the shrouds towards front to release its slot from the fuel
tank lug and separate the shrouds from the fuel tank.

Install in the reverse order of removal.

FUEL TANK
REMOVAL
Turn fuel valve to “OFF” position.
Remove the following:
- Seat (page 2-2).
- Side covers (page 2-2).
Disconnect the fuel feed pipe from the fuel valve.

! WARNING
• Keep petrol away from flames or sparks.
• Wipe up spilled petrol at once. FUEL VALVE FUEL FEED PIPE

Remove the fuel tank mounting bolt, washer and collar.

MOUNTING BOLT

2-6
BODY PANELS/ EXHAUST SYSTEM
DRAIN TUBE
Disconnect the fuel gauge connector from wiring harness.
Disconnect the breather tube and drain tube from the fuel
tank.

CONNECTOR BREATHER TUBE

FUEL TANK
Slide out the fuel tank backward from the tank setting rubber
of frame body.

Installation is in the reverse order of removal.

FAIRING SCREWS
FRONT FENDER COVER
REMOVAL/INSTALLATION
Remove the front wheel (page12-9).
Remove the fairing screws from both side.
Remove two tapping screws from the inner side of the fender
form both sides.

TAPPING SCREW
SLOT TAB
Remove the front fender cover by releasing the tab from the
slot on the fender.

Install in the reverse order of removal.

FENDER COVER

2-7
 BODY PANELS/ EXHAUST SYSTEM

FRONT FENDER
REMOVAL/INSTALLATION
Remove the front wheel (page12-9).
Remove the front caliper mounting bolts and separate the
caliper from the front fork (page12-14). 2

BOLTS
BOLTS
Remove the two fender stay bolts from each side of the front
fender.
Remove the front fender by sliding it down along the length of
the fork.

Install in the reverse order of removal.

BOLTS
SAREE GUARD
REMOVAL/INSTALLATION
Remove the seat (Page2- 2).
Remove the side covers (Page2- 2).
Remove the rear cowl (Page2- 3).
Remove the saree guard mounting bolts (3 nos.) and saree
guard.

Installation is in the reverse order of removal.

NUTS
LEG GUARD
Remove the nuts from the “U” clamp then remove the “U”
clamp.

“U” CLAMP

2-8
BODY PANELS/ EXHAUST SYSTEM

Remove the mounting nut/bolt from the engine hanger plate.

Remove the leg guard.

Installation is in the reverse order of removal.

TORQUE
ENGINE HANGER PLATE NUT: 2.6 kgf-m

NUT
EXHAUST PIPE JOINT NUTS
EXHAUST PIPE/MUFFLER
REMOVAL/ INSTALLATION
Remove the exhaust pipe joint nuts.

Remove the muffler mounting bolt, washer, collar, rubber

and nut.
Remove the muffler and gasket.
NOTE
• Always replace the muffler gasket with a new one
whenever the muffler is removed from the engine.

While installation fix mounting bolt, washer, collar, rubber

and nut first.
Install and tighten the exhaust pipe joint nut, then tighten the
muffler mounting bolt.
BOLT

REAR FENDER
REMOVAL/ INSTALLATION
Remove the seat and side covers (page 2-2).
Remove the rear cowl (page 2-3).
Remove the saree guard (page 2-8).
Remove the rear fender cover mounting screw form the left
side.

SCREW

2-9
 BODY PANELS/ EXHAUST SYSTEM
REAR FENDER COVER
Remove the rear fender cover mounting screw form the right
side.
Remove the rear fender cover.

SCREW

Remove the wiring harness connectors.

Remove the wiring harness routing from the rear fender.

CONNECTORS

Remove the rear shock absorber (page 13-19).

Remove the rear fender mounting bolts from the right side.

BOLTS

Remove the rear fender mounting bolts from the left side.
Remove the rear fender from the frame by pulling it towards
rear carefully.

Installation is in the reverse order of removal.

BOLTS

2-10
MEMO