Service Information


• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.

• 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 gaskets 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 clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.

• Always inspect the exhaust system for leaks after installation.

Excessive exhaust noise

• Broken exhaust system

• Exhaust gas leak

Poor performance

• Deformed exhaust system

• Exhaust gas leak

• Clogged muffler


Upper cowl-to-lower cowl screw Inner half cowl-to-lower cowl screw Windscreen setting screw Seat rail upper mounting bolt/nut Scat rail lower mounting bolt'nut Exhaust pipe joint flange nut Muffler band flange bolt Passenger footpeg flange bolt

2 N-m (0.15 kgf-m, 1.1 Ibf-ft) 2 N-m (0.15 kgf-m, 1.1 Ibf-ft) 1 N-m (0.05 kgf-m, 0.4 Ibf-ft) 49 N-m (5.0 kgf-m, 3G Ibf-ft) 49 N-m (5.0 kgf-m, 36 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft) 23 N-m (2.3 kgf-m, 17 Ibf-ft) 26 N-m (2.7 kgf-m, 20 Ibf-ft)

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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