Removal
Warning: If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries.
1. Remove the rider's seat (see page 16-13).
2. Disconnect the battery, negative (black) lead first.
3. Release the clamp securing the silencer to the header pipe.
1. Silencer; 2. Clamp; 3. Header pipe
4. Support the right hand silencer and release the bolt and nut securing the silencer mounting bracket to the rear frame.
1. Silencer mounting bracket fixing; 2. Nut
Move the silencer rearwards to disengage it from the header pipe and remove.
6. Remove the sump guard (see page 16-24).
Z Disconnect the oxygen sensor from the main harness.
8. Remove the radiator (see page 11-4).
9. Release the fixings securing the header pipe joints to the cylinder head. Discard the fixings.
1. Header pipes; 2. Fixings
10. Remove the bolt from the header pipe rear mounting point.
1. Header pipe rear mounting bolt
11. Detach the header pipe assembly and collect the seals from the cylinder head ports.
12. If necessary, remove the remove the oxygen sensor.
Assembly
1. If removed, install the oxygen sensor and tighten to 25 Nm.
2. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head.
Note: A smear of grease may be used to retain the seals in the cylinder head during assembly.
1. Cylinder head; 2. Seal; 3. Seal tab
3. Locate the header pipes and align the header pipe flanges to the fixing points. Fit new nuts and hand tighten.
4. Assemble the rear mounting point fixing but do not tighten at this stage.
5. Tighten the header pipe to cylinder head nuts in the sequence shown below:
- Stage 1 : Tighten the header pipe nuts to 2 Nm.
- Stage 2: Tighten the header pipe nuts to 19 Nm.
Header Pipe Tightening Sequence
6. Tighten the rear mounting point fixing to 19 Nm.
7. Refit the radiator and refill the cooling system (see page 11-12).
8. Reconnect the oxygen sensor and route the harness under the sump guard as noted on disassembly.
9. Refit the sump guard (see page 16-21).
10. Position and engage the silencer to the header pipe. Do not tighten the clamp at this stage.
11. Align the silencer mounting bracket to the rear frame bracket. Refit the nut. Tighten the fixings to 15 Nm.
1. Silencer mounting bracket fixing; 2. Nut
12. Align the clamp for the silencer to header pipe joint as shown below and tighten to 10 Nm.
1. Silencer intermediate pipe; 2. Clamp; 3. Header pipe
13. Reconnect the battery, positive (red) lead first.
Caution: Do not install the exhaust system or run the engine without the exhaust heatshields fitted. Components protected by the exhaust heatshields may suffer severe damage or a fire if the motorcycle is operated without the heatshields being fitted.
14. Start the engine and check for exhaust gas leaks. Rectify if necessary.
15. Refit the rider's seat (see page 16-13).