Exhaust System - Installation

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
caution
Do not install the exhaust system or run the engine without the exhaust heat shields fitted. Components protected by the exhaust heat shields may suffer severe damage or a fire if the motorcycle is operated without the heat shields being fitted.
  1. Align the exhaust with the cylinder head and loosely fit six lock nuts.
    2. Header Lock Nuts LG1 (ckyp)

    1. Exhaust header

    2. Lock nuts

  2. Make sure the flanged sleeves and grommets are fitted to the two rear exhaust mounts.
  3. Fit the exhaust to the two rear mounts and secure with two fixings and two washers.
    4. Exhaust Rear LG1 (ckyn)

    Right hand side shown, left hand side similar

    1. Fixing

    2. Washer

  4. Tighten the cylinder head lock nuts to 15 Nm in the sequence shown below.
    5. Exhaust header tightening sequence

    Exhaust Header Tightening Sequence

  5. Tighten the two rear mount fixings to 19 Nm.
  6. If required, refit the oxygen sensor to the exhaust and tighten to 25 Nm.
    7. O2 Sensor LG1 (ckyt)

    1. Oxygen sensor

  7. Reroute the oxygen sensor harness as noted during removal and reconnect to the main harness.
  8. Secure the oxygen harness to the coolant hose with two rubber bands.
    9. O2 Sensor Connection LG1 (ckys_1)

    1. Oxygen sensor electrical connector

    2. Rubber band

    3. Coolant tee piece

Perform the following operations

Perform the following operations:

Radiator - Install L Series

Battery - Install L Series

Seat - Install L Series